The Craft
From Sand to Service
Every Willis bell begins as molten silicon brass poured into a sand mold at our foundry. From that pour to final polish, the bell passes through four distinct stages — each performed by hand, to spec, by people who know this work.
The result is the same bell that leaves our shop to serve aboard U.S. Navy destroyers and Coast Guard cutters. When you order a Willis bell, that is the standard you receive.
Molten silicon brass at 1,900°F — the moment the bell begins.
Step 01
The Pour
Silicon brass (C87200) is melted and poured into packed sand molds at approximately 1,900°F. The alloy is specified by the Department of Defense under DOD-B-24673 for naval ship's bell castings. Each pour produces a single bell body.
Moving the ladle at Meloon Foundry, Syracuse, NY.
Step 02
Breaking Out
After cooling, the sand mold is broken away and the raw casting is removed. Flash and sprues are cut, and the bell is inspected before moving to machining. The raw casting weighs more than the finished bell — material is removed at every subsequent step.
Fresh castings — bells at every size, just broken from the mold.
Step 03
Machining
The crown is turned on a lathe and the clapper hole is drilled to precise specification. The mouth of the bell is also turned to ensure the lip is true and will ring cleanly. Brass shavings from this step are collected and returned to the melt.
Drilling the clapper hole. Brass shavings on the floor are swept up and returned to the melt.
Gordon at the polishing wheel. The name patch on the coverall says it all.
Step 04
Hand Finishing
Naval Series bells are hand-polished through multiple stages to a mirror finish. The process begins with coarse abrasives and finishes with fine compounds applied by hand. A mirror-polished Willis bell reflects a true image — that is the DOD-B-24673 finish standard, and it requires hours of work per bell.
Left: raw casting off the mold. Right: mirror-polished and ready to ship.
Marked and Shipped
Made in USA.
Seven sizes. 3 lb through 200 lb. All to spec.
Packaged and strapped — ready for delivery.
Each bell is labeled, strapped, and shipped with documentation. Naval Series bells include a certificate of provenance noting the DOD-B-24673 specification compliance and the Middleville, NY origin.