spaco wrote:
Not quite. They forge both parts to roughly the finished shape. Then
reheat the part that has the box, open the box up enough to insert the
other half through the hole, then, after positioning the halves in the
correct position, forge the parts together. Since this is done below a
welding heat, no bond forms. One reheats the whole thing and forges
the assembly to final shape. Then, the hole is drilled for the pin.
The pin is riveted into place. Then it's file or grind until done.
Pete Ross, previous master blacksmith and manager of the Williamsburg
blacksmith shop for many years makes them often. He says you only need
to make about 25 pairs of box tongs to get good at it.
I bought a completed pair, a pair that are ready to rivet and the
two blanks needed to make another pair at a blacksmith auction in
Asheville, NC some years ago. I had watched him make them.

Thanks, Pete. That was a fascinating explanation. It explains why I
can't see a join in my pliers.

I assume CK have a production line set up which forges the outer part of
the box joint complete with the pre-expanded slot, but I'm just guessing
here. My pliers are CK No. 3772 if anyone else has a pair they'd like to
inspect.

Now there is such a thing as forge welding, isn't there? The monkey
wrenches I'm thinking of are "Trimo" brand. They have a channel which is
box-shaped in cross-section. I've seen one with a crack along the centre
of the channel from overloading. Whether these were forged solid and
later had the channel milled out, or whether the channel was forge
welded, I don't know. Anyone know for sure?

I don't own one, but I'm tempted to buy one now just so that I can
inspect it.

Best wishes,

Chris