From: "Lucinda Sewell" <lucindajohn@sewellhome.freeserve.co.uk>
Date: Mon, 2 Apr 2001 23:18:15 +0100
To: <BiologicalBeekeeping@yahoogroups.com>
Subject: Wax sheets

Hi all,

Sorry Clayton that my reply is a little slow. Erik Osterland has put good
stuff here, I never thought of insulating the part of the dipping vat out of
the heat. What did you use Erik? Temperatures are important I think, I work
as cool as possible all the time. I don't know where I read not to overheat
wax, but it stuck. Maybe why I get sheets too thick if I dip twice?

Did the envelope system make sense to you? Aimed at smaller quantities
really. Make your dipping tank big enough for your board but make it deeper. Your board must be longer than your finished foundation too, mine is about a third longer. I only use one, quantity again I think.
I used ply, soaked in salty water overnight before dipping. I don't have the wax for a thick board. It held up fine through about 50 sheets on one run, and 30 on the next. Still looks good. I put my 'envelope' in a large pot of boiling water. To economise I put smaller pot upside down in the large pot next to it...keeping the bare minimum of liquid as a water jacket. Difficult to
picture, like an upside down glass in water, displacing enough water to save
me some pennies. One day I'll build a double boiler with insulation like
Erik suggests.

My photos suck....a friend is going to try help me light a bit better next
time.

Don't forget that your board will displace wax when you dip it...don't fill
the envelope too high! Hence the longer board too, I can dip when wax is
down to about 1/3 level. Topping up with water works for a while (the wax
floats on the water, still coating the board) but somehow falls down. I
suspect the hot water makes the wax melt off the board or something, I
dunno.

If you read my earlier post and question it I'll answer, I know my
description is often convoluted. I try too hard maybe.

Dee seems to think thin sheets are ok for mangling between boards, the
impressions are distinct with my single dip (I tried regulating my speed,
huh! The speed I found comfortable is my speed, I'll try regulating
temperature when I have facility) but so blurred as to be almost useless on
a double sheet. My goal is size accuracy, not speed of comb building nor
strength for extraction. Several older references to foundation I have read
concentrate on it's use for movable frame hives, and for reducing drone
cells by its worker base pattern.

The actual impression has been ok so far (36 sheets worked, 5 to ten
remelts). I put the sheets in warm water, just warmer than is good for
babies. (If you've never bathed a baby then borrow one...important
experience!) I smother the plates in olive oil, and place cling film food
wrapping plastic on top and oil it too. This all happens on my Kitchen
worktop, with a sponge to mop up the oil, which I squeeze back on again.
Yep...it's also a messy affair. More newspaper on the floor. (Did I mention
Lucinda, my incredibly understanding and patient wife? "As long as you clean
it up darling" Mind you I did rebuild that motorbike in the lounge of the
batchelor pad whilst courting...) The wax comes out of the bath, gets a
shake and goes on the plates and plastic. My plates are bigger than my
sheets, so i can start the plates in alignment and then tighten the rollers
down immediately. I roll to the end, then reverse without losing alignment
and roll the plates right out. The plastic film I replace when it crinkles
too much. Sometimes every time, once I think I got 5 in a row. I ran out of
unscented garbage bags on the day...hence the cling film. The garbage bags
probably last longer when you're over the teething stage (I learnt on sheets
straight from the dipper, instant remelts weren't counted) Do they perfume
garbage bags in the USA? Wierd stuff man...

I hesitate to lock horns with Dave Cushman, he has undoubtably built and
discarded many of the projects still germinating in my newbee brain, but I'm
not sure bees draw out all foundation to comb, or if drawn comb weighs
exactly the same as a sheet of foundation. Comb drawn on bought foundation has a distinct and solid midrib, whereas wild comb has a midrib similar in thickness to a cellwall. This is only my non scientific observation, over 2 seasons, so take it with scepticism.

Well done to those who have made moulds! Keep at it, and scream for help
when it seems impossible. It is possible, and if I can help I will. We're
human beings...creations with the ability to create in our turn. YOU can
make your own foundation. Just do it.
It is messy, time consuming and yet oh so rewarding.

Come on Barry...give us the dope. How many mites did you see? Was it too hot for them? Did you get stung?

John Sewell