Making
a Pitch Lap to Polish Your Telescope Mirror
Baldwin
Old Way
When
grinding your telescope mirror, you had particles tumbling between the mirror and
the tool. They were chipping away at both the tool and the mirror grinding them
into spherical unity, one concave and one convex. Polishing the mirror is
different, the particles aren’t tumbling and they aren’t chipping. There are
going to be particles of Cerium Oxide stuck into microfacets on a platform of
pitch, and when the pitch lap is rubbed against the glass mirror, it will
polish the glass rather than grind (breaking) the glass. For the exact theory
on this chemo-mechanical process, I HIGHLY recommend Mel Bartel’s
site.
Before we
can polish, we need to make a pitch lap. There are as many ways to make a lap
as there are ATMers, and we all have our opinions as to how to do this. And, of
course, all the other ways are wrong. Just kidding, but what I’ll say in this
page will be different than what others will say. That’s OK. Here are a few
ways in which I have made pitch laps.
First of
all, I buy Gugolz 73 pitch. I use it in hot
California weather, and I use 64 when it’s cool. Good stuff. Others will tell
you what they like, I like this stuff. You will need to know how much you’ll
need. I like my pitch laps to be about ¼” thick. So if I am going to cover a
12” tool with ¼” thick layer of pitch, then I will need pr2h cubic inches of
pitch, which would be 3.14 times 6 times 6 times 0.25 = 28 cubic inches of
pitch. A can of Gugolz, if I remember, is about 3.5”
wide and about 6 inches tall, which would be roughly 60 cubic inches of pitch.
If you need more than this, make sure you have two cans ready to use. Always
cook up more than you are going to need.
Read this
before starting. Ever see those instructions when putting something together?
Or are you like me and you start in, and half way through the deal you realize
that you needed something, but the process is already underway, and you’re
screwed? So, here’s the deal. Read this before starting. Once the pitch is
cooking, you will need all your ducks in a row.
Use a pot
that you will never use for anything else again. Once melted pitch is cooked in
a pot, the pot is useless for anything else, especially food. The pot must be
able to be cooked, like a stove top pot with a handle on it. Put your pitch in
it and cook it. I use an electric hotplate. I don’t recommend using one that
uses flames, such as a propane or city gas burner, since pitch is highly
flammable, and has spirits that will flash into flames and burn your house
down. Oh, don’t do this inside, it will stink the place up and your
wife/mother/etc. will kill you. Garages, driveways, and no flammable items
around. Have a fire extinguisher handy.
So, the
pitch is in the pot and is cooking and will eventually melt. While you are
waiting for this, you can get the other stuff ready. Place your mirror clean
side up on the barrel or workbench. It needs to be cleaned. It also helps if it
is very level. Place your tool business end up on the workbench or barrel, next
to the mirror. Wipe the tool with turpentine (or if you’re in California where
everything and its dog is illegal, you can use turpatine,
fake turpentine). Squirt the mirror with Simple Green or some other soap. Some
ATMers use soap, water and cerium oxide to smear on the mirror. Here’s the
deal; the pitch will not stick to soapy stuff very well, and it will adhere
well to stuff with turpentine on it. You will want it to stick to the tool, but
NOT stick to the mirror, while pouring your lap. Don’t mix the two up. I
actually make a slurry out of water, cerium oxide [thick] and soap. It’s like a
release agent.
Once the
pitch has melted into a clumpless goop, kill the
heat. If it is too runny, then let it cool to a clumpless
goop. It ought to look like the black puddle that killed Tash Yar on Star Trek:
The Next Generation. Pour the pitch slowly onto the middle of the level mirror
until it forms a puddle about 2/3 or ¾ the diameter of the mirror. Put the pot
down. Hold the tool by the sides and place it onto the pitch puddle. One of two
things will happen. Either it will stand on the puddle and you’ll have to push
it down, or the puddle will be too runny and it will try to run off the sides
of the mirror, and you’ll have to hold the tool to keep it from pushing the
pitch away. The idea is to let the tool press itself down onto the goop and
push the goop out just to the edge of the tool, but no further. If it is thick
enough, you can let go and let it cool. If it is runny, you’ll have to hold its
weight back so the pitch won’t run off and over, and hold it until it’ll hold
itself without pushing the pitch off, then once it holding you can let go. At
this point you now have (from bottom to top) a mirror, black pitch, and a tool,
all sandwiched together.
Once the
pitch will hold itself, you can flip the whole thing over so the mirror is on
the top and the tool is on the bottom. At that point you can hopefully slide the
mirror off the pitch. If you can, then slide it off, then place it straight
down right back on to the pitch again. The idea is to separate it, then replace
it straight down to make sure it keeps the right shape. If you leave it in
place without this step, you may get a cemented together sandwich that is
really hard to separate. If you do end up with this problem, then let the whole
thing cool off, then lean them against a tree in your yard and run cold hose
water over it. Eventually they will separate. If they don’t, you can tap on one
end of a 2x4 letting the energy travel down through the 2x4 to the other end
where it is against the tool eventually knocking the tool off the mirror. It
will take the pitch with it. This sounds extreme, but the mirror and the tool
with the lap on it will usually survive just fine. You can also put the whole
thing in a bag and put it in the freezer. After a couple of hours, take them
out and the pitch will break off of everything, and you can start all over
again.
OK, read
this once or twice more before starting the lap cooking process.
The lap
isn’t done, but the cooking part is. Now it is time to facet your lap. You will
want to make channels in your lap like a map of a city with north-south streets
and east-west streets. The streets will be about ¼” wide and the blocks will be
about 1.5” square. I use a razor blade and a ruler. Practice is the only way to
make this work well. I usually make two parallel lines with a razor and a
straightedge, ¼ apart, then use the razor to clean out the pitch between them.
Keep the pitch particles clean and return them to the pot to cook again. Make
sure you don’t have an intersection at the center of the lap, and make sure you
don’t have the middle of a block in the center. Making these offset is important
so you don’t polish zones into your mirror. This is not the case for machine
laps though.
Once the
grooves are cut into the lap, it needs to be pressed onto the mirror with
plastic screen door screen between them. This will not only act as an indicator
that all the blocks are in contact by showing the criss-cross
pattern on all blocks, but it will give the lap zillions of little
microfacets in which the cerium oxide will reside while polishing your mirror.
Sometimes
I use a soldering iron to ‘weld’ the pitch to the tool right at the edge of the
tool. This may be useless, but it appears to keep the pitch attached on these
perimeter blocks.
Another
way to make a lap is to pour it onto the tool, which already has turpentine
rubbed on it, and then hot-press the mirror onto it until they conform. Then
cut the grooves. A hot press is when you soak the tool and lap in hot water,
then press the mirror onto it with weights until they have good contact.
New Way
So, I
don’t do this anymore because I bought lap mats. They are a silicon like
material that works like a template, and the pitch is easier to handle. They
const about $40 or $50, but if you do lots and lots of mirrors, it’s worth it.
If you’re only doing 1 mirror, either borrow a lap mat or do it that way I
described above. Anyways, here’s how it works. You cook the pitch. You lay the
mirror face up, clean, not soapy. You lay the lap mat onto the mirror. You pour
the pitch onto the lap mat, then lay the tool onto the pitch on the mat. After
it has cooled, you slide it off and pull the lap mat off the pitch lap. It’s
nearly done, and it’s beautiful. You then chip off the pitch from outside the
circumference, and then press it back onto the mirror [with cerium-soap or a
screen mesh] to press into perfect shape. No mess, easy, clean, looks
professionally done. I love them.
Let’s go
to Polishing and get this
mirror made.