Replacement Caps and Bopper Maintenance

As with all hand tools some practice will be required to obtain proficiency with your new boppers. To prevent excessive pitting and premature wearing out of the copper cap, learn to hit with just enough force to detach the desired flake. Naturally, your billet will last longer if used against softer heat treated stones, but sooner or later the cap may need to be dressed, or re-shaped if it has become too nicked, or pitted to work well making clean flake removals more difficult. Filing may re-dress the surface of the head if it isn’t too bad. However, keep in mind you are removing copper off the thin cap. If the cap has become deeply pitted, or cratered, then the hemispherical shape of the head may be somewhat restored by hammering. When lead finally stars to show, it is time to replace the cap by following the instructions below.

1. Apply heat to the cap with a small propane torch. Use just enough heat to melt the glue without burning the wood, however some scorching may occur. When you start to smell the glue the cap should come off easily when grasped and twisted with pliers. Eye and hand protection are recommended while performing this operation.

 2. Sand the inside of the new cap to prepare a clean, ruff surface for both the lead and the glue to adhere to. Now, melt the lead out of the old cap and let it pore into the new one. Make sure the new cap is held level by another set of pliers, or place it in an indentation in the ground. Also, I pre-heat the new cap, then, to make doubly sure I get a good bond between the lead and the copper I will apply more heat till the surface of the lead is flat inside the cap, then I let it cool.

3. After the cap has cooled to room temperature, liberally apply epoxy glue to the inside of the cap and replace it on the handle evenly. For best results, use 30 minute epoxy and let cure overnight. Note: caps may very in length and some adjustments may be needed to seat them properly. Check before gluing. If there is excess space between the lead and the end of the handle after seating against the shoulder, fill in the space with extra glue, or you can add more lead!

Replacement caps are available here! When ordering your tools you might want to consider adding an extra cap or two, especially for the small 3/4, and 1 inch sizes. These see the most action!       

This product was added to our catalog on Sunday 23 February, 2014.

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