Skylighter Fireworks Tips
February 7, 2003 -- Issue #47

If you are ordering novelty fireworks, books, or videos, no ID is required. You do not have to send in the Hold Harmless or a copy of your driver’s license. If you order anything else, you do have to send us your ID and accept or sign our Hold Harmless Agreement. This is just to clarify some of your questions.

GETTING LEGAL, CONTINUED...

Jim Biersach writes about his experiences in applying for and complying with ATF regulations:

"Well I saw your newsletter, and thought that you may like to know that I have already taken someone's advice, and have a Type 20, High Explosive Manufacturing License in the works. It's going to be in the 40's here this weekend, sort of summer like for us tough guys from Wisconsin, and I should have magazine done and ready for the state and federal inspectors. It wasn't as hard as I thought, and actually the ATF agents are real people, and can understand me and answer questions. A pyro buddy has helped me a lot. I taught him how to lay concrete block, and I don't even know how to do it myself. It has taken three months of weekends to put this up. If you want I can send a photo of it. This weekend, I have a pal coming to weld the door on, and I have a little carpentry to do inside to cover up that evil steel."
It can be a lot simpler than you may think to get yourself in compliance with local, state, and federal regulations if you are manufacturing fireworks. The first thing to do is to go online or to your public library and check the local and state laws applying to you. Check the state and local fire code, although there may be other laws, which cover your situation as well.


If you order $200 or more worth of stuff from us between now and 5:00 PM, Tuesday, February 11, you can take one unit of of any of our tubes (if we have them in stock) at absolutely no charge. You must order online, and you must tell us in the comments section of your online order that you want this freebie. This offer is limited to the first 5 people who order $200 and ask for the freebie. And yes, you can take this freebie AND take advantage of the special offer below.

HOW TO MAKE SAXONS, PART 2, BY JOHN WERNER

VARIATIONS ON SAXONS

1. The saxon described is a 2-tube version connected with a wooden dowel. This is the best method for making large saxons. Smaller, shorter versions can also be made using a single tube without a dowel. The ramming sequence would be: clay plug, composition, clay plug separator at the middle of the tube, composition, and clay plug, using the entire length of the tube. The clay plug separator in the middle allows you to drill a hole for the pivot point. The disadvantage of this style is that the holes need to be drilled after the ramming has been completed.
2. Have both nozzle holes point in the same direction. This causes the saxon to revolve first in one direction and then in the reverse direction as it transfers to the other tube.
3. Have both tubes light at the same time; nozzle holes must be pointed in opposite direction. The saxon will spin much faster, but the burn time is reduced by half.
4. Use multiple formulas in each tube for more color changes.
5. Attach color pots (like short, stubby lance) to the side of the saxon; this produces bright rings of color inside a halo of sparks.
6. Use longer tubes with multiple formulas in each tube and multiple nozzle holes all matched to burn at the same time. This results in a halo of sparks with several color rings inside. The Chinese make a great version of this.
7. Use four (or more) tubes. Instead of a single wooden dowel, make up a cross-shaped piece that allows four tubes to be mounted for extended effect capability and burn time.
8. Try combinations of above suggestions.

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TECHNICAL NOTES: BASIC HAND RAMMING TECHNIQUE, PART ONE

INTRODUCTION

For anyone wishing to progress beyond making items such as bangers or salutes, it is necessary to become familiar with the techniques of consolidating pyrotechnic compositions in a tube. Known as charging or ramming, the oldest and most common method is done by hand with a mallet and drift. This technique is easy to learn and can be used for making such items as rockets, fountains, gerbs, spolettes, saxons, and drivers. The process is still widely used in large scale manufacturing plants and in many instances is a faster and definitely cheaper method of loading composition than trying to use small hydraulic jacks and presses. It is especially versatile when making up prototypes or small numbers of devices. A major drawback to hand ramming is that it is unsuitable for friction or shock sensitive compositions, such as those used for strobe or whistle rockets.

EQUIPMENT & MATERIALS

1. MALLET: Generally wood, rawhide or rubber "dead blow" mallets work best. A broad face is preferable and the mallet should be large enough that its weight does most of the work, rather than your arm. Avoid steel carpenter or machinist's hammers. Some people like a round mallet of the type woodworkers use for striking chisels.
   
   
2. RAMMERS (DRIFTS): These are simply rods or dowels made to fit the internal diameter (I.D.) of the tube being loaded. They should be an easy slide fit without binding on the walls of the tube. If too loose however, the surface of the powder will not be properly compacted near the tube walls. Suitable materials include wood, brass, stainless steel, aluminum, and some plastics. Each material has a different "feel" when ramming. Plastic, such as PVC rod, has limited use and has a very spongy feel when struck. However, it is cheap, easy to cut and holds up well. Wood is also cheap and easy to cut and shape. Hardwoods, like birch or maple, have a fine, even grain and have a more solid feel than plastic. Wood is simple to reduce in diameter without complicated machinery if a slightly looser fit is required. It is soft enough that if the face of the rammer accidentally strikes the spindle used to form a clay nozzle, there will be little or no damage done to the spindle (which is usually metal, and can be costly to replace). There is less chance too of accidentally causing any powder to ignite if pinched between spindle and rammer. Metal rammers made from brass, aluminum, or stainless steel have a very nice, heavy, solid feel, but may be expensive and hard to machine without a lathe. Brass is especially nice to use in small (3/8" or less) diameters, when wood is not rigid enough. Wood is fine for most other instances, and is an inexpensive way of building an inventory of rammers in different diameters and lengths. Steel should not be used because of spark hazards.
   
   
3. RAMMING POST: In order to get even, solid consolidation of material, a suitable support surface is needed underneath the item being loaded. There is nothing worse than trying to ram on a weak or springy surface. Ideally, the ramming surface should be a post with a smooth level top held upright by being buried part way in the ground. The actual top does not need to be more than four to six inches square. It should be as heavy and solid as possible. Material can be wood or cast concrete. If a portable post is desired, it can be a section of railroad tie, a section of 6x6 beam, or a tall box made of plywood and filled with sand. A cap made from medium density fiberboard (MDF board), solidly attached to the top of the post makes a great smooth surface that is easy to brush clean. Avoid cracks or crevices in the post where loose powder can collect. Always separate the ramming surface from whatever table or surface is used to hold the powder being rammed. If this is not done, the vibrations from the ramming process will tend to separate the components of the unused composition. The arrangement of post and table should be of a convenient height and layout such that all tools, powder, and finished devices have a designated location to make the ramming process go smoothly. Having tubes and drifts rolling off the table interrupts the flow of work and increases chances for accidents. Locating everything within easy reach will make the work go much more quickly with fewer mistakes.
   
   
4. TUBES: For the most part, parallel or convolute wound tubes are used when hand ramming compositions. A convolute wound tube is made by wrapping a single sheet of paper around a metal mandrel. The mandrel's diameter is the required internal diameter of the tube. The length of the paper when rolled up completely will determine the wall thickness of the tube. Convolute tubes can be machine rolled or hand rolled if an unusual size is needed. Generally, heavy walled tubes are used in order to withstand the blows from the ramming process and to keep the tube from splitting. Thinner walled tubes can be used also if properly supported in sleeves and molds (this will be covered more thoroughly in another article). Purchased tubes come either cut to length (with nice square ends) or in longer sections straight from the rolling machine (which you can cut the length needed). Unless one owns a lathe to make a clean cut, a chop saw with a fine tooth blade will give a good square, albeit somewhat fuzzy, end.
   
   
5. CLAY: The most convenient and widely used method for plugging tubes and making nozzle orifices is to use dry powdered clay. Bentonite clay (Skylighter # CH8078) works well, as is, for most applications. Many people like to treat the clay with additives such as wax, various oils, or graphite to cut down on dust and to facilitate its loading and packing qualities.
   
   
6. PYROTECHNIC COMPOSITONS: Hand ramming as opposed to pressing with pneumatic or hydraulic presses, can be more dangerous when utilizing mixtures that are friction and shock sensitive. Black powder based formulas used in fountains, gerbs, and rockets are generally safe, although the inclusion of metals such as titanium should be treated with caution and respect. KNOW YOUR COMPONENTS.
   
   
7. SAFETY: Any loading and ramming of pyrotechnic devices should be done in a remote area, preferably outdoors in an area protected from the wind. Powder in the area should be limited only to the material being used and in uncovered amounts not exceeding one or two pounds. A good quality dust mask should always be worn when hand ramming, as there will always be dust floating in the immediate area. Follow all standard safety rules concerning static, sources of ignition, etc., which one adheres to when working with any pyrotechnic process.

Order $131.31 worth of anything from Skylighter between now and Tuesday, February 11, 2003, and get 5 pounds any oxidizer we sell, absofreakinlutely free of charge. Deadline is 5:00 PM, February 11, 2003. See fine print below or... well, you know. New Twist: To take advantage of this deal, you must order from our web site. Use the comments section of the shopping cart to tell us that you want the Free Oxidizer deal.


Wade through it now or weep later. This fine print is different from the last fine print. It supersedes all previous fine print.

- You have to place your order using the shopping cart on our web site. To take advantage of this deal, you cannot fax your order in, phone your order in, mail your order in, nor wish it was here.

- You have to ask for the Free Oxidizer Deal, when you place your order-not retroactively. Use the comments section of your order to ask for it.

- You have to place your order on our web site before 5:00 PM, Eastern Time (US) on the deadline date above (not Kuala Lumpur time, not Central, Rocky Mt. nor Pacific Time).

- You have to ask for this deal when you place your order-you're not allowed to forget and then remember. You can’t order yesterday and get this deal today. We will not apply it to the last order you placed, no matter how much we love you, nor how good a customer you have convinced yourself you are.

- The minimum order total cannot include anything showing as "Temporarily Unable to Ship" or "Not Shippable" on our web site unless you’re gonna pick it up or have us deliver it. The minimum order total cannot include shipping charges or sales taxes.

- All Oxidizers are hazardous chemicals. We cannot ship any hazardous materials outside of the US.

- This offer is limited to Oxidizers, which we can ship. You cannot get any oxidizers for free which we cannot ship-even if you want to pick it up.

- This offer applies to US addresses only. Anything you order must be shipped to a United States address (may include Alaska, Islands, US territories, etc. so long as they have a US zip code). It is okay by us if you are a Canadian, a Mexican, or any other non-United States’er, trying to beat the system, as long as you do it by having us ship your order to a US address. This offer does not apply to our former Al Quaeda customers currently residing at our Caribbean resort at Guantanamo Bay. And, no, we will not make an exception because you want to put on a neat fireworks display just to entertain your military guards. Yes, we know they’re bored.

- No funny money will be given or taken on your order if you take advantage of this special offer.

- If you order $131.31 worth of stuff, you can get 5 pounds any Oxidizer free (except those which currently cannot be shipped). If you order $262.62 worth of goods, you can get 10 pounds free, and so on. If you order $131.30 wortha stuff, you don't get nothin' fer free! We are tough sonsabeeches!

- You have to ask for this deal specifically. You can’t just request "Whatever Specials You Have Right Now" or words to that effect into your order. You can’t call us and ask us what the current freebie is-we won’t tell you. There’s a reason for this. We only offer these deals to alert, sentient beings. We do not offer them to folks who don’t read our email bulletins or who haven’t figured out that they can go to our web site and read about our freebies before placing their orders.

- You pay any shipping costs on free items.

- You have to prepay your order before the deadline by giving us your credit card number. You cain't place the order, and get us to hold it for you, until your allowance/alimony/social security check comes. Neither should you entertain any fantasies about first placing the order and then asking us to wait for your check, or ID, or permission from your old lady. Nosireebob!

- We have to receive your ID and Hold Harmless (or you must have accepted the Hold Harmless Agreement on our web site) by the deadline. You can’t send your order and send your papers later, after the deadline.

- You have to ask for this deal when you place your order-right then; at the same time; in the comments block of yer web site order. NOT when you're talking to us on the phone; NOT in the fax you send; NOT in the letter you mail; NOT in the chicken scratchings wrapped around the yer homing pigeon's leg; NOT in the same bottle your order washed up in; NOT on the same flying carpet your messenger flew in on; NOT wrapped around the same rock that crashed through our winder here; NOT stuck in the same hole in the same tree trunk; NOT in the exact same puff of smoke you signaled your order with.

- This deal cannot be combined with any other specials or discounts, except the $200 Bonus Freebie described above. You already know this though, so why do you keep trying? NOOOO, DAMMIT. N-O. No.

- No, we won't give you this deal on the order you have already sent us; nor can you call us and tell us you forgot to mention it, because remember? You didn't ask for the deal back then! You must use at least 5% of your remember-power to get this deal.

- Yes, we really did conspire to send out this deal right after we got your huge order at full price! You KNOW we did! Must have!


Someone sent us some outrageously good and alcoholic chocolate nut balls for Christmas. The return address on the box was not readable. If you’re the culprit, please let us know who you were. Those things are incredible! I may never have to go the liquor store again.