Paul Hamler Photos

Paul Hamler With a Miniature Woodworking Tool

Paul displaying one of his miniature tools at the 2003 Cabin Fever show in York, PA.

Powder Flasks

Powder flasks in various sizes sit next to Paul’s tiny Davis level.

Paul’s Briefcase of Miniatures

Another picture of Paul’s briefcase from the Cabin Fever show (2003). Note the saws tucked into the flap on the lid of the case.

Paul’s Briefcase of Miniatures

Various Miniatures

A separate glass-covered display case houses some of Paul’s spokeshaves, powder horns, and an ornate slotting plane.

Paul’s Tools

A few of Paul’s tools sit in his case.

Charles G. Miller Patent Plane

This finely detailed plane was photographed in a display box at the Cabin Fever show, with a quarter for scale reference.

Full-Size Miller Patent Plane

This is a photo of the original full-size Miller Patent plane for comparison. Considering its size, Paul’s model captures an amazing amount of the original’s fine detail.

Miller Patent Plane Casting

A pattern master for casting the brass fence for the Miller plane.

Miniature Plane

A plane made from brass and dark hardwood sits among tools in Paul’s case.

The Original Rabbit Plane

With tongue firmly in cheek, Paul presented the Joe Martin Foundation with one of his fun pieces, which he calls, “the Original Rabbit Plane.” The model is actually a tiny functional plane, and while it may not be very ergonomic, it is certainly charming. A quarter gives reference to the small size.

Wooden Block Plane

Various Miniature Tools

Some of Paul’s past projects.

Various Miniature Tools

Fleetwood Treadle Saw

Another treadle scroll saw by Fleetwood of Wilmington, DE, from around 1884. This model was also made at a scale of 7.5:1.

Fleetwood Treadle Saw

Note the fine casting detail, this time left in natural brass and wood.

Stanley Type 4 Multi-Plane

This angled view of the multi-plane shows it as it would have been seen in catalogs of its era. In those days, a good craftsman expected their tools to last a lifetime. The care put into these tools, and their ornate decoration, reflects the importance a craftsman places on the quality of their tools and work.

Stanley Type 4 Multi-Plane

This model was made in 1/3 scale, and captures all the fine details of the original.

Paul’s Old Workshop

Another look inside Paul’s old workshop.

Paul’s New Workshop

Pictured here is Paul’s new 1800 square-foot workshop.

Miniature Plane

A folding ruler is placed next to one of Paul’s planes.

Long Rifle Firing Mechanism

In this photo, the firing mechanism for the rifle is seen at full-size, 1/2 size, and 1/3 size. This image dramatically illustrates how much smaller 1/3 scale really is—even when compared to 1/2 scale. While this increases the challenge of making small parts, 1/3 scale yields a final product that is small enough to be considered “miniature,” while also exhibiting all the details and function of the original.

Long Rifle Progress

Checking the fit of the flintlock on a partially completed stock.

Machining the Stock

Paul Casting Parts

Paul pours raw metal to cast some parts.

Brass Parts

A “tree” of brass parts ready for trimming.

Flintlock Firing Mechanism

The flintlock mechanism with engraving. Note the dime for size reference.

Pneumatic Engraving Tools

Hand Tools

Paul uses a large selection of hand tools for carving and engraving.

Casting Process

The molding and casting process shows the full-size part, the scaled down mold, a model of the part, a wax of the model, and the final cast piece.

Engraving Setup

The setup for engraving includes a stereo microscope. This makes it possible to see the fine detail when using a pneumatic engraving tool.

Silver Inlay

A silver piece formed over a pattern, before it was inlaid.

Silver Inlay

The silver inlay is pressed into a slot carved into the final workpiece.

Patchbox Cover

The engraved patchbox cover in place on the stock.

Brass Butt Plate

A brass butt plate installed on an unfinished stock.

Long Rifle Stock

A closer look at some of Paul’s stock carving.

Finishing the Long Rifles

Several models are shown in various states of finish. All that’s left is to stain and finish the stock.

Kentucky Long Rifles

Three finished miniature Kentucky long rifles on display.

Lost-Wax Process

Once a master pattern for each part is made, the molds for wax casting are created. The pink wax seen here has the sprues attached. (A sprue is the pathway for metal to flow into the mold.) The wax is then encased in a plaster mix. After the plaster dries, the wax is heated up and flows out—leaving a detailed cavity. The cavity is then filled with molten metal.

Lost-Wax Process

Once everything cools down, the plaster cast is broken, leaving the metal part. This is called the lost-wax process. While it may be slow, it produces very detailed, high quality parts. This photo shows some of the wax parts compared to their full-size counterparts.

Wax Parts

Cast Metal Parts

The cast parts are still attached to their sprues.

Assembled Colt M1911 Pistol

A fully assembled scale pistol with grip.

Colt 1911 Frames

The full-size original frame (black) sits below Paul’s 1/3 scale cast frame.

Colt Magazine

The first step in making the magazine is to bend sheet brass.

Colt Magazine

This photo shows the sheet metal magazine form.

Magazine Spring

A lathe is used to wrap wire around a piece of rectangular metal to make the magazine spring.

Colt 1911 Pistol With Springs

Finished Magazine

The finished magazine loaded with dummy rounds.

Engraving Process

The engraving process starts with marking where the design will go.

Engraving Process

The major shapes are then cut.

Engraving Process

The main pattern is filled in with hand-engraved details.

Colt Castings and Parts

Sets of castings and parts for Paul’s Colt miniatures. Before the final assembly is completed, the functional miniature weapons will have the appropriate parts either blued or nickel plated. Paul would later add different grips and engraving on some pistols.

Finished Miniature Colt Pistol

A finished miniature Colt in its display case—a remarkable piece of craftsmanship.