The first task was to cut the folded bellows card, 18 folds, into the correct lengths for the ends and sides, and at the correct angle, slightly less than 45 degrees. This was done by binding the tightly folded card with masking tape and using a circular power saw. The cardboard turned out to be tougher than wood and this was the only way that I was able to cut it accurately.

Now comes what I would call "the bitter bit", as the four prepared sections of bellows card have to be supported in some way whilst diamond shaped leather fillets are glued to each corner. It is now some time since I made the bellows, but I seem to remember a litany of clips and temporary paper fillets. The leather fillets were glued to the insides of the corners, metal corners were fitted and crimped to the outside. The pointed corners had to be trimmed to accommodate these. The bellows folds were lined on the outside with fabric strips before the metal corners were fitted and afterwards strips of bellows tape were applied to each fold with PVA glue.

Each end of the bellows was attached to rectangular wood frame to which was fitted a smaller frame to fit inside the cases. The frames are held in place with the conventional bellows pins (4 at each end).

The glue used throughout the construction was PVA white glue. However a washable white glue as used in schools was used for the bellows so as to facilitate possible future repairs. This will allow old tape to be removed without taking away the surface of the bellows card.

These bellows have turned out to be completely airtight, though rather stiff at first. The stiffness has now worn of with use.

4 Construction

4.2 Bellows