The first duty that Lord Rosse had to undertake was the construction of this tremendous mirror, six feet across, and about four or five inches thick. The dimensions were far in excess of those which had been contemplated in any previous attempt of the same kind. Herschel had no doubt fashioned one mirror of four feet in diameter, and many others of smaller dimensions, but the processes which he employed had never been fully published, and it was obvious that, with a large increase in dimensions, great additional difficulties had to be encountered. Difficulties began at the very commencement of the process, and were experienced in one form or another at every subsequent stage. In the first place, the mere casting of a great disc of this mixture of tin and copper, weighing something like three or four tons, involved very troublesome problems. No doubt a casting of this size, if the material had been, for example, iron, would have offered no difficulties beyond those with which every practical founder is well acquainted, and which he has to encounter daily in the course of his ordinary work. But speculum metal is a material of a very intractable description. There is, of course, no practical difficulty in melting the copper, nor in adding the proper proportion of tin when the copper has been melted. There may be no great difficulty in arranging an organization by which several crucibles, filled with the molten material, shall be poured simultaneously so as to obtain the requisite mass of metal, but from this point the difficulties begin. For speculum metal when cold is excessively brittle, and were the casting permitted to cool like an ordinary copper or iron casting, the mirror would inevitably fly into pieces.
Lord Rosse, therefore, found it necessary to anneal the casting with extreme care by allowing it to cool very slowly. This was accomplished by drawing the disc of metal as soon as it had entered into the solid state, though still glowing red, into an annealing oven. There the temperature was allowed to subside so gradually, that six weeks elapsed before the mirror had reached the temperature of the external air. The necessity for extreme precaution in the operation of annealing will be manifest if we reflect on one of the accidents which happened. On a certain occasion, after the cooling of a great casting had been completed, it was found, on withdrawing the speculum, that it was cracked into two pieces. This mishap was eventually traced to the fact that one of the walls of the oven had only a single brick in its thickness, and that therefore the heat had escaped more easily through that side than through the other sides which were built of double thickness. The speculum had, consequently, not cooled uniformly, and hence the fracture had resulted. Undeterred, however, by this failure, as well as by not a few other difficulties, into a description of which we cannot now enter, Lord Rosse steadily adhered to his self-imposed task, and at last succeeded in casting two perfect discs on which to commence the tedious processes of grinding and polishing. The magnitude of the operations involved may perhaps be appreciated if I mention that the value of the mere copper and tin entering into the composition of each of the mirrors was about 500 pounds.