Chapter 9
"Ranged in rows on either side of a long room of the button factory, (says the correspondent of the Morning Chronicle) are from 50 to 100 girls and young women, from the age of fourteen to four or five and twenty, all busily engaged, either at hand or steam presses, in punching out metal circles slightly larger than the size of the button which is to be produced. Before each press the forewoman is seated, holding in her hand a sheet of zinc or iron, about two feet long, and four inches broad. This she passes rapidly under the press if worked by hand, and still more rapidly if worked by steam, punching and cutting at the rate of from fifty to sixty disks in a minute. As they are cut they fall into a receptacle prepared to receive them. The perforated sheets are sold to the founder to be melted up, and made into other sheets. In other rooms younger women are engaged in cutting up Florentine cloth, or other outside covering material, paste board and calico. Of these a young woman can punch 57,000 a-day, and of metal, 28,000 a-day. The upper discs are submitted by another set of girls to presses from which each receives a blow that turns up an edge all round, and reduces it to the exact size of the button. The lower disk is punched for the shank to come through, stamped with the maker's name, or the name of the tailor for whom the buttons are made, and coated with varnish, either light or black.
"The five pieces then pass into a department where a woman superintends the labours of a number of children from seven to ten years of age.
"These little creatures place all five pieces, one after another, in regular order, in a small machine like a dice-box, constructed to hold them, which is placed under a press, when a firm touch compresses the whole together in the neat form, which any one may examine on a black dress coat, without stitch or adhesive matter."
This patent was the subject of long litigation between rival inventors, to the great benefit of the lawyers, and loss of the industrious and ingenious.
Within the last twelve months Messrs. Chadbourne, button-makers, of Great Charles Street, have adapted this Florentine button to nails for furniture and carriages.
The Patent Linen sewn-through Button is another recent invention, which has superseded the old wire button for under garments, than which it is cheaper, neater, and more durable. It is composed of linen and circles of zinc.
Horn Buttons, with shanks, which are extensively used for cloth boots and sporting jackets, are made from the hoofs of horned cattle, which are boiled, cut, punched, dyed, stamped when soft, and polished by brushes moved by steam power; the chief part of the work being done by women and children.
Pearl Buttons have become an important part of the Birmingham manufactures, partly on the decline of metal buttons. They are extensively used on coats and waistcoats, where gilt buttons were formerly employed.
The shell used in the manufacture of buttons, studs, card counters, etc., is the mother of pearl, the Concha margaritifera of naturalists. Five kinds of shell are employed:--First. The Buffalo Shell, so named because it arrived packed in buffalo skins; it comes chiefly from Panama, is the smallest and commonest, and sells to the trade at about 15 pounds a ton.--Second. The Black Scotch, from the Sandwich Islands, whence it is sent to Valparaiso and to Sydney, New South Wales, worth from 15 to 30 pounds a ton. The large outer rim is of a blackish, or rather greenish, tint, the centre only being white. The outer rim was formerly considered worthless, and large quantities were thrown away as rubbish. Change of fashion has brought the prismatic hues of the dark pearl into fashion for shooting-coats, waistcoats, and even studs. It used to be a standing story with a Bristol barber that a square in that city had been built on thousands of pounds worth of tobacco stalks, thrown away as useless, until it was discovered that that part of the plant was capable of making a most saleable snuff. And so in Birmingham; the Irvingite Church, on New Hall Hill, is said to be built on hundreds of tons of refuse shell, which would now be worth from 15 to 20 pounds per ton. The third shell is the Bombay, or White Scotch, worth from 20 to 50 pounds per ton. The fourth comes from Singapore, and is brought there to exchange for British manufactures by the native craft which frequent that free port. It is a first-rate article, white to the edge, worth from 80 to 90 pounds per ton. The fifth is the Mother of Pearl Shell, from Manilla, of equal value and size, but with a slight yellow tinge round the edge.
Pearl buttons are cut out and shaped by men with the lathe, polished by women with a grinding-stone, and sorted and arranged on cards by girls.
Glass Buttons were formerly in use among canal boatmen, miners, and agricultural labourers, in certain districts. They are now chiefly made for the African market. The process of making them and studs is well worth seeing.
Beside the buttons already enumerated, they make in Birmingham the flat iron and brass buttons, for trowsers; steel buttons, for ladies' dresses; wooden buttons, for overcoats; agate buttons, for which material is imported from Bohemia; and, in fact, every kind of button and stud, including papier mache.
The manufacture of brass shanks is a separate trade, and the writer of the letters already quoted, states the annual production at, or upwards of, three millions per working day. Of these, part are made by hand, but the greater number by a shank-making machine, wrought by steam power, and only requiring the attendance of one tool-maker.
"The machine feeds itself from a coil of brass or iron wire suspended from the roof, and cuts and twists into shanks, by one process, at the rate of 360 per minute, or nearly 75,000,000 per annum. Some button manufacturers employ one of these machines; the majority buy the shanks."
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GUNS AND SWORDS.--According to Hutton, the historian of Birmingham, the town was indebted for its occupation in supplying our army with fire-arms, to an ancestor of a gentleman who now represents a division of Warwickshire, a Sir Roger Newdigate, in the time of William III.
The story, however, seems only half-true. Hutton would imply that the first muskets manufactured in England were made in Birmingham. It seems more likely, that the connexion with William III. arose from the desire of that monarch to have the flint-lock, which was superseding the match-lock on the Continent, made in his own dominions.
At any rate, the revolution of 1688, which the romantic anti-commercial party of Young England so deeply regret, gave Birmingham its gun trade, as well as Hampton Court its asparagus beds.
When Walpole gave us peace, the attention of the manufacturers was directed to fowling-pieces, and from that time forward Birmingham has contained the greatest fire-arm factory in the world, although, of course, subject to many fluctuations. Twenty years ago, "A long war soon," was as regular a toast at convivial meetings of Birmingham manufacturers, as at any mess-room or in any cock-pit in her majesty's service.
The government has made several attempts, by establishing manufactories with public money and under official control, to become independent of Birmingham, but the end has invariably been great loss and pitiful results in the number of arms produced.
We hope to live to see the time when our navy will be built as economically as our guns are made--by private contract--and our public ship-yards confined to the repairing department.
During the war which ended at the battle of Waterloo, the importance and prosperity of the gun-makers were great. It was calculated that a gun a minute was made in Birmingham on the average of a year, but the Peace threw numbers out of work and reduced wages very considerably.
Time has brought the trade to a level; indeed, it is one of the great advantages of Birmingham, that the prosperity of the town does not rest on any one trade; so that if some are blighted others are flourishing, and when one fails the workmen are absorbed into other parallel employments.
The gun trade now depends for support on the demand for--first, cheap muskets for African and other aboriginal tribes; secondly, on cheap fowling-pieces, rifles, pistols, blunderbusses, etc., for exportation to America, Australia, and other countries where something effective is required at a moderate price; thirdly, on the home demand for fowling-pieces of all qualities, from the commonest to those sold at the West End of London, at fancy prices; fourthly, on that for fire-arms required by our army and navy; and, lastly, on occasional uncertain orders created by wars and revolutions on the Continent.
There are a vast number of guns, or parts of guns, made in Birmingham, which bear the names of retailers in different parts of the kingdom. Even very fashionable gun-makers find it worth their while to purchase goods in the rough state from Birmingham manufacturers on whom they can depend, and finish them themselves.
This is rendered easy by the system. No one in Birmingham makes the whole of a gun. The division of labour is very great; the makers of the lock, the barrel, and the stock, are completely distinct, and the mechanics confine themselves to one branch of a department. The man who makes the springs for a lock has nothing to do with the man who makes the nipple or the hammer; while the barrel-forger has no connexion with the stock-maker or lock-maker.
The visitor who has the necessary introductions, should by no means omit to visit a gun-barrel factory, as there are a good many picturesque effects in the various processes, beside the mechanical instruction it affords.
The following is the order of the fabrication of a common gun:--
The sheets for barrels are made from scraps of steel and iron, such as old coach-springs, knives, steel chains, horse shoes and horseshoe nails, and sheets of waste steel from steel pen manufactories.
These, having been sorted, are bound together, and submitted first to such a furnace, and then to such a steam hammer as we described in our visit to Wolverton, until it is shaped into a bar of tough iron, which is afterwards rolled into sheets of the requisite thickness.
From one of these sheets a length sufficient to make a gun barrel is cut off by a pair of steam-moved shears, of which the lower jaw is stationary and the upper weighs a ton, of which plenty of examples may be seen in every steam engine factory.
The slip of iron is made red hot, placed between a pair of rollers, one of which is convex and the other concave, and comes out in a semicircular trough shape; again heated, and again pressed by smaller rollers, by which the cylinder is nearly completed. A long bar of iron is passed through the cylinder, it is thrust into the fire again, and, when red hot, it is submitted to the welder, who hammers it and heats it and hammers it again, until it assumes the form of a perfect tube.
Damascus barrels are made by incorporating alternate layers of red hot steel and iron, which are then twisted into the shape of a screw while at white heat. The bar thus made is twisted in a cold state by steam power round a bar into a barrel shape, then heated and welded together.
These are the barrels which present the beautiful variegated appearance which gives them the name of Damascus.
The barrels, whether common or twisted, are then bored by a steel rod, kept wet with water or oil, and turned by steam. The process occupies from two to three hours for each barrel.
The next operation is that of grinding the outside of the barrel with sandstone wheels, from five to six feet in diameter when new, driven by steam. These stones chiefly come from the neighbouring district of Bilston; in four months' work, a stone of this size will be reduced to two feet.
The employment is hard, dangerous from the stones often breaking while in motion, in which case pieces of stone weighing a ton have been known to fly through the roof of the shop; unwholesome, because the sand and steel dust fill eyes, mouth, and lungs, unless a certain simple precaution is taken which grinders never take.
After grinding, a nut is screwed into the breech, and the barrel is taken to the proof house to be proved.
The proof house is a detached building, the interior of which is lined with plates of cast iron.
The barrels are set in two iron stocks, the upper surface of one of which has a small gutter, to contain a train of powder; in this train the barrels rest with their touchholes downwards, and in the rear of the breeches of the barrels is a mass of sand. When the guns, loaded with five times the quantity of powder used in actual service, have been arranged, the iron-lined doors and windows are closed, and a train extending to the outside through a hole is fired.
Some barrels burst and twist into all manner of shapes; those which pass the ordeal are again examined after the lapse of twenty-four hours, and, if approved, marked with two separate marks, one for viewing and one for proving. The mark for proving consists of two sceptres crossed with a crown in the upper angle; the letters B and C in the left and right, and the letter P in the lower angle. For viewing only, V stands instead of P underneath the crown, the other letters omitted.
After proving, the jiggerer fastens the pin, which closes up the breech.
In the mean time the construction of the lock, which is an entirely different business, and carried on in the neighbouring towns of Wednesbury, Darleston, and Wolverhampton, as well as in Birmingham, has been going on.
The gun lock makers are ranged into two great divisions of forgers and filers, beside many subdivisions.
The forgers manufacture the pieces in the rough, the filers polish them and put them together. In the percussion lock, there are fifteen pieces; in the common flint lock, eight.
By a process patented about eleven years ago, parts of a gun lock formerly forged by hand are now stamped with a die. The use of this invention was opposed by the men, but without success.
The barrel and lock next pass into the hands of the stocker.
The stocks, of beechwood for common guns, of walnut for superior, of which much is imported from France and Italy, arrive in Birmingham in a rough state. The stocker cuts away enough of the stock to receive the barrel, the lock, the ramrod, and shapes it a little.
The next workman employed is the screw-together. He screws on the heel plate, the guard that protects the trigger, puts in the trigger plate, lets in the pipes to hold the ramrod, puts on the nozzle cap, and all other mountings.
After all this, a finisher takes the gun to pieces, and polishes, fits all the mountings, or sends them to be polished by women; the lock is sent to the engraver to have an elephant and the word "warranted," if for the African market, put on it; a crown and the words "tower proof," if for our own military service; while the stock is in the hands of the maker off and cleanser, it is carved, polished, and, if needful, stained.
Common gun barrels are polished or browned to prevent them from rusting, real Damascus barrels are subjected to a chemical process, which brings out the fine wavy lines and prevents them from rusting.
All these operations having been performed, the barrel, the lock, and the stock, are brought back by the respective workmen who have given them the final touch, and put together by the finisher or gun maker, and this putting together is as much as many eminent gunmakers ever do. But, by care and good judgment, they acquire a reputation for which they can charge a handsome percentage.
For these reasons, with local knowledge, it is possible to obtain from a Birmingham finisher who keeps no shop, a first-rate double gun at a very low figure compared with retail prices.
Belgium and Germany compete with Birmingham for cheap African guns, and even forge the proof marks. Neither in quality nor in price for first-rate articles can any country compete with us.
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SWORDS AND MATCHETTS.--The sword trade of Birmingham is trifling compared with that in guns. The foreign demand has dwindled away until it has become quite insignificant, and the chief employment is afforded by our own army and navy. Nevertheless, good swords are made in Birmingham, which is the only town in England where any manufacture of the kind exists, although the blades often bear the names of more fashionable localities.
It is among the traditions of the Birmingham trade, that in 1817, when our Government was about to transfer its orders for swords to Germany, in consequence of the inferiority of English swords, a Mr. Gill claimed to compete for the contract; and that in order to show what he could do, he appeared before the Board of Ordnance with a sword, which he tied round his thigh, and then untied, when it immediately became straight. In the end Mr. Gill was the means of retaining the sword trade in Birmingham.
Sword-grinding is worth seeing. Sword-makers find their principal employment in producing Matchetts, a tool or weapon very much like the modern regulation cutlass, but stronger and heavier, with a plain beech-wood handle, worth wholesale from 6d. to 9d. each. They are used in the East and West Indies, Ceylon, and South America, for cutting down sugar-canes and similar uses. We take the name to be Spanish; it is used by Defoe and Dampier. We only mention the article as one of the many odd manufactures made, but never sold retail, in England.
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STEEL PENS.--All the steel pens made in England, and a great many sold in France, Germany, and America, whatever names or devices they may bear, are manufactured in Birmingham. In this respect, as in many others of the same nature, the Birmingham manufacturers are very accommodating, and quite prepared to stamp on their productions the American Eagle, the Cap of Liberty, the effigy of Pio Nono, or of the Comte de Chambord, if they get the order, the cash, or a good credit. And they are very right; their business is to supply the article, the sentiment is merely a matter of taste.
There are eighteen steel pen manufacturers in the Birmingham Directory, and eight penholder makers. Two manufacturers employ about 1,000 hands, and the other seventeen about as many more.
We can most of us remember when a long hard steel pen, which required the nicest management to make it write, cost a shilling, and was used more as a curiosity than as a useful comfortable instrument. About 1820, or 1821, the first gross of three slit pens was sold wholesale at 7 pounds 4s. the gross of twelve dozen. A better article is now sold at 6d. a gross.
The cheapest pens are now sold wholesale at 2d. a gross, the best at from 3s.6d. to 5s.; and it has been calculated that Birmingham produces not less than a thousand million steel pens every year. America is the best foreign customer, in spite of a duty of twenty-four per cent; France ranks next, for the French pens are bad and dear.
Mr. Gillott, who is one of the very first in the steel-pen trade, rose by his own mechanical talents and prudent industry from a very humble station. He was, we believe, a working mechanic, and invented the first machine for making steel pens, which for a long period he worked with his own hands; he makes a noble use of the wealth he has acquired; his manufactory is in every respect a model for the imitation of his townsmen, as we shall show when we say a few words about the condition of the working population; a liberal patron of our best modern artists, he has made a collection of their works, which is open to the inspection of any respectable stranger.
The following description of his manufactory, which is not open to strangers without special cause shown, will be found interesting in a social as well as a commercial and mechanical point of view.
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GILLOTT'S STEEL-PEN FACTORY.--In the first department, sheets of steel received from Sheffield are passed through rolling mills driven by steam, under charge of men and boys, until they are reduced to the thinness of a steel pen, to the length of about thirty inches, and the breadth of about three inches. These steel slips are conveyed to a large roomy workshop, with windows at both sides, scrupulously clean, where are seated in double rows an army of women and girls, from fourteen to forty years of age, who, unlike most of the women employed in Birmingham manufactories, are extremely neat in person and in dress. A hand press is opposite each; the only sound to be heard is the bump of the press, and the clinking of the small pieces of metal as they fall from the block into the receptacle prepared for them. One girl of average dexterity is able to punch out one hundred gross per day. Each division is superintended by a toolmaker, whose business it is to keep the punches and presses in good working condition, to superintend the work generally, and to keep order among the workpeople.
The next operation is to place the blank in a concave die, on which a slight touch from a concave punch produces the shape of a semitube. The slits and apertures which increase the elasticity of the pen, and the maker's or vendor's name, are produced by a similar tool.
When complete all but the slit, the pens are soft and pliable, and may be bent or twisted in the hand like a piece of thin lead. They are collected in grosses, or great grosses, into small square iron boxes, and placed by men who are exclusively employed in this department in a furnace, where they remain until box and pens are of a white heat. They are then taken out and immediately thrown hissing into oil, which cures them of their softness, by making them as brittle as wafers. On being taken out they are put in a sieve to drain, and then into a cylinder full of holes, invented by Mr. Gillott, which, rapidly revolving, extracts the last drop of moisture from the pens, on a principle that has been successfully applied to drying sugar, salt, and a vast number of other articles of the same nature. By this invention Mr. Gillott saves in oil from 200 to 300 pounds a-year.
The pens having been dried are placed in other cylinders, and polished by mutual friction, produced by reverberatory motion. They are then roasted or annealed, so as to procure the requisite temper and colour, whether bronze or blue. The last process is that of slitting, which is done by women, with a sharp cutting tool. One girl, with a quick practised finger, can slit as many as 28,800 pens in a day. They are now ready for the young girls whose duty it is to count and pack them in boxes or grosses for the wholesale market.
It has lately been stated by one of a deputation to the Chancellor of the Exchequer, on the subject of the paper duties, that steel pens for the French market are sent in bags instead of arranged on cards to the loss of paper makers and female labour, in consequence of the heavy excise duty on card board.
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