Italian (or better said Italio-American) style
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Introduction of materials, tools, and
techniques for building cylinder shells.
The construction method derives from
Italians that migrated to the USA and
continued their efforts Stateside. Hence
Italio-American.
Techniques blend even further with the
change of materials that are available per
generation. Technology such as the internet
spawns self starters which also initiates
change from tight knit family type operations.
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As more people enter the hobby, their
reasoning or interpretation changes based on
what materials are available to the fireworker.
Sometimes this is a good thing and
sometimes a bad thing. Must fully understand
task at hand when modifing!
Best to avoid short cuts. Short cuts usually
revert to inferior material and/or design.
Please ask questions as we progress!
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“The intent of the Fulcanelli article was to
describe the typical catalogue shells that an
Italian-American company would have made
fifty years ago and the method that was used
to make them. That method is a
simplification of the methods used earlier and
still used for shells larger or longer than
those listed in the article”
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Pyrotechnica IX (April 1984)
Pyrotechnica XI (June 1987)
◦ Books can be found online at some pyro suppliers
 American Fireworks News (AFN)
 Warren Klofkorn of Prometheus
(prometheus.publications@cox.net)
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Passfire.com
Fireworking.com
Amerature Pyrotechnics and Chemistry (APC)
RecPyro Google Group
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Club Members
Pyrotechnics Guild International (PGI)
A good mix of interaction with different
people is needed to share all items
pyrotechnic!
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It’s all about $$$$!
Use what you can get your hands on!
◦ Maybe….maybe not.
Some tools and material can be made to save
money.
Charcoal
Formers
Avoid inferior material as much as possible.
Corrugated cardboard
Weak spolette tubes
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Formers
Calipers
Spiking Tools
Spolette Tooling
Canulles
Turacciolo (plug for
break)
Spolette Rammer
Awl or punch
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Different Paper Cutters
Brushes
Blender
Screens
Dead Blow Hammer
Shell Roller
Alpax Circle Cutter
Shell Press
Forstner Bits
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Paper
Paste
String
Shell Case
End Discs
Liners
Paste Wraps
Black Match
Burst
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Garnitures
◦ Stars
◦ Comets
◦ Inserts
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Pipe (for passfire)
Spolettes
Time Fuse
Buckets
Passfires
Lift
Grain Long
Grain Short
Grain Long
Grain Short
Shell Size
Case Former
Diameter
Minimum Length
of Former
(Nominal shell size
x 2 plus 1”)
3”
2-1/2”
7”
4”
3-1/2”
9”
5”
4-1/2”
11”
6”
5-1/2”
13”
7”
6-1/4”
14”
8”
7-1/4”
16”
10”
9”
19”
12”
11”
25”
Paper Weight
Paper Thickness
(in inches)
30 lb
.003”
40 lb
.004”
50 lb
.005”
60 lb
.006”
70 lb
.007”
90 lb
.009”
70 pound paper is normally used. Thinner paper could be used and
would require additional turns.
Shell Size
Number of Turns
on Former
Paper Length
3”
3
24”
4”
4
48”
5”
5
3 each 24”
6”
6
4 each 24”
7”
7
3 each 48”
8”
8
4 each 48”
Shell Size
Number of turns
On former
Paper Weight
Paper Length
3”
3
30-40 lb.
24”
4”
4
50-70 lb.
48”
5”
5
60-70 lb.
3 each 24”
6”
6
60-70 lb.
4 each 24”
7”
7
60-70 lb.
3 each 48”
8”
8
70 lb.
4 each 48”
Shell Size
Canulle Diameter
3”
3/4” – 1”
4”
1” – 1-1/4”
5”
1-1/2” – 1-3/4”
6”
1-3/4” – 2”
7”
2” – 2-1/4”
8”
2-1/4” – 3”
Shell Size
Verticals/Strands
Material
3”
12/2
8 Ply Cotton
4”
16/2
8 or 10 Ply Cotton
5”
24/2
8 or 10 Ply Cotton
6”
32/2
8 or 10 Ply Cotton
7”
32/2 - 48/2
8 or 10 Ply Cotton
8”
48/2
8 or 10 Ply Cotton
Shell Size
Inside Dia.
Outside Dia.
Length
Powder Charge
3”
5/16”
.55”
2”
1” – 1-1/4”
4”
5/16” – 3/8”
11/16”
3”
1-3/8”
5”
5/16” – 3/8”
11/16”
3”
1-3/8” – 1-1/2”
6”
5/16” – 3/8”
11/16”
3”
1-1/2”
7”
5/16” – 3/8”
11/16”
3”
1-1/2 – 1-3/4”
8”
5/16” – 3/8”
11/16”
4”
1-3/4”
Shell Size
Delay Time (seconds)
3”
3
4”
3.5
5”
4
6”
5
7”
5-6
8”
6
The length of fuse will depend on the burn rate for that particular
fuse. Usually 3 seconds per inch is close but does need to be
verified!
Time fuse not recommended for cylinder shells!
Shell Size
Description
Weight of 2FA Lift Powder
3”
Color or Salute
1 oz
3”
Color and Inserts
1-1/4- 1-1/2 oz
4”
Color or Salute
2 oz
4”
Color and Inserts
2-1/2 oz
5”
Color or Salute
3 – 3-1/2 oz
5”
Color and Inserts
4 -5 oz
6”
Color or Salute
4-5 oz
6”
Color and Inserts
4-1/2 – 6 oz
7”
Color and Inserts
6 - 7 oz
8”
Color
8 – 12 oz
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Wheat Paste
Mix as directed on package. Usually heavier paper will need more water and
lighter paper will need less.
Recycled paper will like less water.
Maltese Paste
900 grams water
600 grams Elmer’s white glue
120 grams wheat paste (dry)
10 grams Potassium or Sodium Benzoate (preservative)