US20060150357A1

US20060150357A1 - Stainless steel tool and method of forming

Info

Publication number: US20060150357A1
Application number: US11/034,931
Authority: US
Inventors: Carl Bongiovanni
Original assignee: Bon Tool Co
Current assignee: Bon Tool Co
Priority date: 2005-01-13
Filing date: 2005-01-13
Publication date: 2006-07-13

Abstract

Mortar joint finishing tools, such as jointers, beaders, and sledrunners are disclosed. The tools may include a stainless steel body. The tools and may be formed by a method such as casting, forging, or stamping.

Description

BACKGROUND OF THE INVENTION

Finishing tools are applied to masonry or masonry mortar joints during construction to treat the masonry or mortar joints. These tools include jointers, sledrunners, and beaders, which contact unhardened mortar in joints during operation to provide a finish.

SUMMARY OF THE INVENTION

The present invention is directed to masonry mortar joint finishing tools, such as various types of jointers, sledrunners, and beaders. In one embodiment, a masonry mortar joint finishing tool includes a stainless steel (“stainless steel” refers herein to various known or future developed stainless steel alloys) body. The jointer includes a cast stainless steel first mortar-contacting element having a first mortar-contacting surface with a first contour. The jointer may further include a second mortar-contacting element adjacent the first mortar-contacting element and having a second mortar-contacting surface with a second contour. A connecting element may be formed to and between the first mortar-contacting element and the second mortar-contacting element in an embodiment.
The body's stainless steel form provides high strength, hardness, and durability, and a high corrosion resistance which should remain high even after surface wear and damage.
The body may be manufactured by a method that provides further advantageous properties. One method may be casting, which provides good dimensional repeatability among multiple manufactured bodies. Another method may be forging, which provides a body with high directional strength, structural integrity, and toughness. Yet another method of manufacture may be stamping, which provides a body at a lower production cost and a lower material cost.
In another embodiment, a cast stainless steel jointer includes a first element with a first surface, wherein the first surface has a first contour configured to impart a first shape or indent in an unfinished mortar joint. The jointer may also include a second element having a second surface, wherein the second surface has a second contour configured to impart a second shape or indent in the unfinished mortar joint. The jointer may also include a connecting element that extends between the first element and the second element.
In another embodiment, a sledrunner includes a stainless steel body that includes an elongated mortar-contacting element having a mortar-contacting surface and a handle support affixed to the elongated mortar-contacting element and configured for fastening to a handle.
In another embodiment, a stainless steel beader includes a first element having a first surface, wherein the first surface has a first contour configured to impart a first form to an unfinished mortar joint. The beader may also include a second element having a second surface, wherein the second surface has a second contour configured to impart a second form to the unfinished mortar joint. A connecting element may extend between the first element and the second element.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is better understood in conjunction with the accompanying drawings, in which like reference characters represent like elements, as follows:
FIG. 1 is a perspective view of an embodiment of a jointer;
FIG. 2 is a side view of the embodiment of FIG. 1;
FIG. 3 is a left end view of the embodiment of FIG. 1;
FIG. 4 is a right end view of the embodiment of FIG. 1;
FIG. 5 is a top view of the embodiment of FIG. 1
FIG. 6 is a perspective view of another embodiment of a jointer;
FIG. 7 is a side view of the embodiment of FIG. 6;
FIG. 8 is a top view of the embodiment of FIG. 6;
FIG. 9 is a perspective view of an embodiment of a sledrunner;
FIG. 10 is a side view of the embodiment of FIG. 9;
FIG. 11 is a left end view of the embodiment of FIG. 9;
FIG. 12 is a top view of the embodiment of FIG. 9;
FIG. 13 is a perspective view of an embodiment of a beader;
FIG. 14 is a side view of the embodiment of FIG. 13;
FIG. 15 is a left end of the embodiment of FIG. 13;
FIG. 16 is a right end view of the embodiment of FIG. 13; and
FIG. 17 is a top view of the embodiment of FIG. 13.

DETAILED DESCRIPTION

Because of the demands inherent in their operation, the bodies of jointers, sledrunners, and beaders are subject to deterioration.
Cast zinc alloys, malleable iron, and brass alloys, such as bronze, are forms used for the bodies of jointers, sledrunners, and beaders. But, because the strength, hardness, and corrosion resistance of these materials is mediocre, bodies made from these materials still lack durability over prolonged use.
Another material used in the main bodies of jointers, sledrunners, and beaders is high carbon steel. However, high carbon steel lacks good corrosion resistance, decreasing the durability of bodies made from this material.
Additionally, the bodies of jointers, sledrunners, and beaders are commonly sanded or ground to a finish, resulting in rough surfaces that cause friction when slid against mortar during operation.
One method of improving the durability of jointers, sledrunners, and beaders is to coat them with a corrosion-resistant material. For example, a body of a jointer may be plated with chromium, which has good corrosion resistance. However, the coating will eventually wear off from use.
In one embodiment of a masonry mortar joint finishing tool as shown in FIGS. 1-5, a jointer 10 includes a stainless steel body 20 that includes a first mortar-contacting element 30, a second mortar-contacting element 40, and a connecting element 50 that extends between the first and second mortar-contacting elements 30 and 40.
FIG. 2 shows a side view of the body 20 of the jointer 10. The body 20 may be shaped in an “S” configuration as shown from the perspective of FIG. 2. The first mortar-contacting element 30 may be parallel to the second mortar-contacting element 40 as shown from the perspective of FIG. 2, if desired. However, the body 20 may be differently shaped. For example, the body 20 may be shaped as any of various sigmoid configurations, where the first and second mortar-contacting elements 30 and 40 are or are not parallel, and the body 20 is symmetrical or asymmetrical.
The body 20 may also be shaped such that the connecting element 50 is variously angled with respect to the first and second mortar-contacting elements 30 and 40. For example, the connecting element 50 may have first and second portions 52 and 54 that are rounded as viewed from the perspective of FIG. 2. Alternatively, the first and second portions 52 and 54 may be shaped such that the connecting element 50 forms distinct angles with respect to the first and second mortar-contacting elements 30 and 40. The connecting element 50 may also be flat or otherwise shaped in a middle portion 56.
The first mortar-contacting element 30 in the embodiment of FIGS. 1-5 includes a first end 32 and a first outer surface 34. From the perspective of FIG. 2, the first end 32 and the first outer surface 34 may intersect such that the angle between them is less than 90 degrees. However, various angles may be employed. A portion or all of the first outer surface 34 in this embodiment contacts unfinished mortar during operation of the jointer 10, dependent upon the size of the mortar joint.
FIG. 3 shows a left end view of the jointer 10. From the perspective of FIG. 3, and taken as a plane perpendicular to the longitudinal axis of the first mortar-contacting element 30, the first mortar-contacting element 30 in this embodiment has a “U” shaped cross section, and the mortar-contacting first outer surface 34 has a cross-section that has a convex, “U” contour. Thus, during operation of the jointer 10, the cross-sectional “U” contour of the outer surface 34 may be pressed and/or slid against unhardened mortar in a masonry construction to impart a rounded, concave indent to the mortar.
However, the cross-sections of the shape of the first mortar contacting element 30 and the contour of the first outer surface 34 may be variously designed, such as with cross-sections having a “V” shape and contour, a “T” shape and square or step contour, a hollow or solid square shape and flat contour, a hollow, solid, or half circle shape and half-circle contour, an oval shape and half-oval contour, or another shape and/or contour as desired. The various designs for cross-sectional contours of the first outer surface 34 may impart different indents to unhardened mortar during operation of the jointer 10.
The second mortar-contacting element 40 in the embodiment of FIGS. 1-5 includes a second end 42, and a mortar-contacting surface, the second outer surface 44. From the perspective of FIG. 2, the second end 42 and the second outer surface 44 may intersect such that the angle between them is less than 90 degrees. However, as with first end 32 and the first outer surface 34, various angles may be employed. From the perspective of FIG. 2, the angle between the second end 42 and the second outer surface 44 may be the same as or different than the angle between the first end 32 and the first outer surface 34.
In another embodiment, the jointer 10 does not include the connecting element 50, and the first and second mortar-contacting elements 30 and 40 abut.
In another embodiment that is not illustrated, the connecting element 50 of the jointer 10 includes a protruding threaded element at each of its ends, for coupling with replaceable first and second mortar-contacting elements 30 and 40. The first and second mortar-contacting elements 30 and 40 in this embodiment have apertures with complementary threading to that of the connecting element 50, such that they may be screwed onto the connecting element 50. The first and second mortar-contacting elements 30 and 40 may be replaced by other threaded mortar-contacting elements of various sizes and shapes. Other coupling configurations may alternately be used. Such a jointer may be configured and shaped like a “barrel” jointer, as known in the art.
In another embodiment that is not illustrated, the jointer 10 does not include the second mortar-contacting element 40, and instead includes a handle, such as a cylindrical wooden or plastic handle, in its place. The handle may be secured to or around a portion of the body 20, such as by epoxy and/or interference fit. The body 20 may extend into an opening in the handle, to facilitate the securing.
FIG. 4 shows a right end view of the jointer 10. From the perspective of FIG. 4, and taken as a plane perpendicular to the longitudinal axis of the second mortar-contacting element 40, the second mortar-contacting element 40 in this embodiment has a “U” shape cross section, and the cross-section of the second outer surface 44 has a convex, “U” contour. The cross-sectional shape of the second mortar-contacting element 40 may be different than that of the first mortar-contacting element 30, and may have any of the shapes mentioned with respect to the first mortar-contacting element 30, as described above, or another shape. The curved portion of the cross-sectional “U” contour of the second outer surface 44 may have a different radius than the curved portion of the cross-sectional “U” contour of the first outer surface 34. Thus, where the second outer surface 44 is pressed and/or slid against unhardened mortar, the shape of the imparted indent may be different than that imparted by the first outer surface 34. The second outer surface 44 may also have a cross-sectional contour other than a “U,” such as described with respect to the first outer surface 34.
FIG. 5 shows a top view of the jointer 10. From this perspective, the body 20 may be straight as shown, or a different shape. The connecting element 50 may be bowed.
FIGS. 6, 7, and 8 show a perspective, side, and top view, respectively, of an example of a jointer with mortar-contacting elements with different shapes and contours. In this embodiment, a bullhorn jointer 110 includes a first mortar-contacting element 130 having a first mortar-contacting surface, the first outer surface 134. The bullhorn jointer 110 illustrated in that embodiment also includes a second mortar-contacting element 140 having a second mortar-contacting surface, the second outer surface 144.
The first mortar-contacting element 130 in this embodiment has a rounded shape that bends toward its end 132 as shown from the perspective of FIG. 7, and narrows toward its end 132 as shown from the perspectives of FIGS. 6, 7 and 8. The cross-sectional shape of the first mortar-contacting element in this embodiment, as taken as a plane perpendicular to the longitudinal axis of the first mortar-contacting element 130, is a solid circle or solid oval that becomes smaller nearer the end 132. The cross-section of the outer surface 134 in this embodiment is thus configured as a circle or oval that is smaller nearer the end 132, and may impart a narrow, rounded indent in unhardened mortar in a mortar joint.
The second mortar-contacting element 140 in this embodiment also has a circular or oval cross-sectional shape, but the shape does not narrow toward the second end 142. Thus, the cross-section of the mortar-contacting surface, outer surface 144, is circular or oval and may impart a rounded indent in unhardened mortar that is larger than that imparted by the outer surface 134.
In another embodiment of a masonry mortar joint finishing tool as shown in FIGS. 9-12, a sledrunner 210 includes a stainless steel body 220 that includes a mortar-contacting element 230, and a handle support 240 affixed to the mortar-contacting element 230 and configured for fastening to a handle. A handle 250 may be fastened to the handle support 240.
FIG. 10 shows the side view of the body 220 of the sledrunner 210. The mortar-contacting element 230 in this embodiment is elongated, and straight over most of its length, as shown from the perspective of FIG. 10. But, the mortar-contacting element 230 may be curved or angled up at its first end 232 and second end 234, which may facilitate sliding of the sledrunner 210. In this embodiment, the mortar-contacting element 230 includes an elongated mortar-contacting surface, the outer surface 236. The outer surface 236 length, which may span much or all the distance between the first end 232 and the second end 234, may facilitate operation of the sledrunner 210 on long mortar joints.
FIG. 11 shows a front end view of the sledrunner 210. From this perspective, and taken as a plane perpendicular to the longitudinal axis of the mortar-contacting element 230, the mortar-contacting element 230 in this embodiment has a cross-section having a “V” shape, and the outer surface 236 has a cross-section that has a “V” contour. However, these cross-sections may be different, such as described with respect to the first mortar-contacting element 30 and first outer surface 34 of the jointer 10 in FIGS. 1-5, or in other embodiments.
Returning to FIG. 10, the sledrunner 210 in this embodiment includes a handle support 240, which may be attached to or formed on and project from the top surface 260 of the mortar-contacting element 230. The handle support 240 may include a first bracket 242 having a first aperture 244, and a second bracket 246 having a second aperture 248. The handle support 240 may be affixed to the top surface 260 in various ways. For example, the handle support 240 may include an anchoring member 249 that is affixed to the top surface 260. The anchoring member 249 may be stainless steel or another material and may be flat or may conform in shape to the top surface 260. The anchoring member may extend between and be affixed to the first bracket 242 and the second bracket 246.
In one embodiment, the first bracket 242, second bracket 246, and anchoring member 249 may be formed as a unitary structure. The anchoring member 249 may then be secured to the top surface 260 by solder, weld, or another method. The body 220 may also be formed as a unitary structure that includes a handle support 240 that does not include an anchoring member 249, such as where the body 220 is cast or forged.
In another embodiment that is not illustrated, the body 220 may be formed as a unitary structure that includes a handle support for securing to a handle. The handle may be secured to or around a portion of the handle support, such as by epoxy and/or interference fit. The handle support may extend into an opening in the handle, to facilitate the securing. In this embodiment, the body 220, handle support, and handle may be configured as and into the shape of a “loop” sledrunner, as known in the art, in which the handle support includes a portion that extends, in the shape of a curve, from one end of the body 220 to the handle.
Returning to the embodiment shown in FIGS. 9-12, a handle 250 may be secured to the first and second brackets 242 and 246 through their apertures 244 and 248, respectively, such as by screws or a bolt.
FIG. 12 shows a top view of the sledrunner 210. As viewed from this perspective, the handle 250 may be positioned at the center of the mortar-contacting element 230, or off-center.
In another embodiment of a masonry mortar joint finishing tool as shown in FIGS. 13-17, a beader 310 includes a stainless steel body 320 that includes a first mortar-contacting element 330, a second mortar-contacting element 340, and a connecting element 350 that extends between the first and second mortar-contacting elements 330 and 340.
FIG. 14 shows the body 320 of the beader 310. In this embodiment the body 320 is shaped in an “S” configuration as shown from the perspective of FIG. 14. The first mortar-contacting element 330 is also parallel to the second mortar-contacting element 340 in this embodiment. The connecting element 350 may have first and second portions 352 and 354 that are rounded as viewed from the perspective of FIG. 14.
However, the body 320 may have a different shape as viewed from the perspective of FIG. 14, such as any shape described with respect to the jointer 10 as viewed from the perspective of FIG. 1. Thus, the body 320 may have different shapes and angles with respect to its first mortar-contacting element 330, second mortar-contacting element 340, and connecting element 350.
The first mortar-contacting element 330 in the embodiment of FIGS. 13-17 includes a first end 332 and a first inner surface 334. From the perspective of FIG. 14, the first end 332 and the first base 333 of the first inner surface 334 may intersect such that the angle between them is 90 degrees. However, various angles may be employed. Likewise, the second end 342 and the second base 343 of the second inner surface 344 may intersect at a 90 degree angle, or another angle.
A portion or all of the first inner surface 334 in this embodiment may contact unhardened mortar in a mortar joint during operation of the beader 310.
FIG. 15 shows a left end view of the beader 310. From the perspective of FIG. 15, and taken as a plane perpendicular to the longitudinal axis of the first mortar-contacting element 330, the first mortar-contacting element 330 in this embodiment has a “U” shaped cross section, and the first inner surface 334 has a cross-section that is a concave, “U” shaped contour. Thus, during operation of the beader 310, the “U” shaped contour of the first inner surface 334 may be pressed and slid against unhardened mortar in a masonry construction to impart a rounded, convex form in the mortar. Thus, a beader may provide a raised mortar joint, whereas a jointer may provide an indented mortar joint.
However, the cross-sectional shape of the first mortar-contacting element 330 and the cross-sectional contour of the first inner surface 334 may be different, such as a “V” shape and contour, a hollow square shape and square contour, a hollow half-circle shape and half-circle contour, a half-oval shape and half-oval contour, or another shape and/or contour as desired. The various alternatives for cross-sectional contours of the first inner surface 334 may impart different forms to unhardened mortar during operation of the beader 310.
FIG. 16 shows a right end view of the beader 310. From the perspective of FIG. 16, and taken as a plane perpendicular to the longitudinal axis of the second mortar-contacting element 340, the second mortar-contacting element 340 in this embodiment has a “U” shape cross section, and the second outer surface 344 has a cross-section that has a convex, “U” contour. The shape of the second mortar-contacting element 340 may be different than that of the first mortar-contacting element 330. The curved portion of the cross-sectional “U” contour of the second outer surface 344 may have a different radius than the curved portion of the cross-sectional “U” contour of the first outer surface 334. Thus, where the second outer surface 344 is pressed and slid against unhardened mortar, the shape of the imparted form may be different than that imparted by the first outer surface 334. The second outer surface 344 may have another cross-sectional contour, such as described with respect to the first outer surface 334, to impart a form to unfinished mortar.
In another embodiment not illustrated, the beader 310 does not include the second mortar-contacting element 340, and instead includes a handle, such as a cylindrical wooden or plastic handle, in its place. The handle may be secured to or around a portion of the body 320, such as by epoxy and/or interference fit. The body 20 may extend into an opening in the handle to facilitate the securing.
FIG. 17 shows a top view of the beader 310. From this perspective, the body 320 may be straight as shown, or a different shape. The connecting element 350 may be bowed.
Constructing the body of a masonry mortar joint finishing tool with stainless steel (“stainless steel” refers herein to various known or future developed stainless steel alloys) provides many advantageous properties in comparison to constructions with other metals, such as zinc alloys, malleable iron, and brass alloys, such as bronze. These properties are due, in part, to the high chromium content of stainless steel, which contributes to its high hardness, and its wear and corrosion resistance.
The corrosion-resistant properties of stainless steel include the ability of stainless steel to inherently form a protective film of chromium-rich oxide at its surfaces. If the surface film is penetrated or worn away due to chipping, scratching, or other surface-damage, the newly-exposed surface may spontaneously regenerate a surface film in the presence of the oxygen in air. This property provides an advantage in stainless steel over a different metal body that is plated with corrosion-resistant material, since when the plating wears off from use, that other metal body's corrosion resistance may significantly decrease, and its surface hardness may suffer with use. The surface hardness of stainless steel, however, typically remains high even after prolonged use.
The material of the masonry mortar joint finishing tool body in any of the above embodiments may be a stainless steel grade in the 400 series. Series 400 grades are martensitic stainless steels and have high hardness, impact strength and corrosion resistance. They may also be heat treated to increase their hardness. One series 400 stainless steel that may be used is grade 431, which has the best corrosion resistant properties of the martensitic steels.
Alternatively, where even higher corrosion resistance is desired, a 300 series austenitic stainless steel may be used for the body. One grade that may be used is 304L stainless steel, which has excellent corrosion resistance properties.
The body of a masonry mortar joint finishing tool may be manufactured to have desired properties. One such manufacturing method may be casting. Casting the body may provide better dimensional repeatability as compared with other production forms. The method of casting used to produce the masonry mortar joint finishing tool body may be casting. A form of casting is investment casting (also known as the “lost wax” method of casting), which provides excellent dimensional repeatability. Other methods may also be used, such as die-casting or sand casting.
The body of a masonry mortar joint finishing tool manufactured by investment casting may be more than fifty percent harder and two-hundred percent stronger than current bodies cast from zinc and brass alloys, and malleable iron.
In another embodiment, the body of a masonry mortar joint finishing tool may be formed by forging. Forging provides the body with high directional strength, structural integrity, and toughness. One method of forging may be the conventional closed die method. One form of stainless steel used in the forging process may be powdered stainless steel. Powdered stainless steel may be pressed into shape at a high pressure, sintered, and then forged. Other forms of stainless steel may also be used for forging a body.
Manufacturing the body by casting or forging may also provide more durability over other methods. For example, casting or forging may produce a body that is thicker and thus more wear resistant and longer lasting than a body formed with sheet metal. Additionally, a tool with a cast or forged body may be heavier and thus more sturdy and comfortable to a user, as compared with a body formed of sheet metal.
In another embodiment, the body of a masonry mortar joint finishing tool may be formed of sheet metal stainless steel. This body may be formed by stamping. Where the body has multiple pieces, the pieces may be secured to each other by spot welding.
Once the body of the masonry mortar joint finishing tool has been formed, it may be polished to a mirror-finish. Methods which may be applied include using a buffing wheel and a belt with a polishing compound. Polishing will provide a smooth tool working surface that minimizes drag when the surface slides against concrete during operation.
The foregoing description has been directed to specific embodiments of this invention. It will be apparent, however, that other variations and modifications may be made to the described embodiments, with the attainment of some or all of their advantages. It will also be appreciated that features described with respect to one embodiment may be applied to another, whether explicitly indicated. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention.

Claims

1. A mortar joint finishing tool, comprising:

a cast stainless steel first mortar-contacting element having a first mortar-contacting surface, the first mortar-contacting surface having a first contour; and

a cast stainless steel second mortar-contacting element adjacent the first mortar-contacting element and having a second mortar-contacting surface, the second mortar-contacting surface having a second contour.

2. The mortar joint finishing tool of claim 1, wherein the casting is investment casting.

3. The mortar joint finishing tool of claim 1, wherein the first mortar-contacting element and the second mortar-contacting element are polished.

4. The mortar joint finishing tool of claim 1, wherein the first contour is convex.

5. The mortar joint finishing tool of claim 1, wherein the first contour is concave.

6. The mortar joint finishing tool of claim 1, wherein the first mortar-contacting element has a longitudinal axis and a cross-section, the cross-section a plane taken perpendicular to the longitudinal axis, wherein the cross-section is shaped as a “U.”

7. The mortar joint finishing tool of claim 1, wherein the first mortar-contacting element has a longitudinal axis and a cross-section, the cross-section a plane taken perpendicular to the longitudinal axis, wherein the cross-section is shaped as a “V.”

8. The mortar joint finishing tool of claim 1, wherein the first contour is different than the second contour.

9. The mortar joint finishing tool of claim 1, wherein the stainless steel is martensitic stainless steel.

10. The mortar joint finishing tool of claim 1, wherein the stainless steel is austenitic stainless steel.

11. The mortar joint finishing tool of claim 1, further comprising a cast stainless steel connecting element extending between the first mortar-contacting element and the second mortar-contacting element.

12. The mortar joint finishing tool of claim 11, wherein the connecting element is formed with the first mortar-contacting element and the second mortar-contacting element.

13. A cast stainless steel jointer comprising:

a first element having a first surface, the first surface having a first contour configured to impart a first indent in an unfinished mortar joint;

a second element having a second surface, the second surface having a second contour configured to impart a second indent in the unfinished mortar joint; and

a connecting element that extends between the first element and the second element.

14. The cast stainless steel jointer of claim 13, wherein the casting is investment casting.

15. The cast stainless steel jointer of claim 13, wherein the first element has a first shape, and the second element has a second shape, and wherein the first shape is different than the second shape.

16. The cast stainless steel jointer of claim 13, wherein the first contour is different than the second contour.

17. A sledrunner comprising a stainless steel body that comprises:

an elongated mortar-contacting element having a mortar-contacting surface; and

a handle support affixed to the elongated mortar-contacting element and configured for fastening to a handle.

18. The stainless steel sledrunner of claim 17, wherein the handle support comprises two brackets adapted for fastening to a handle.

19. The stainless steel sledrunner of claim 17, wherein the stainless steel sledrunner is formed by casting.

20. The stainless steel sledrunner of claim 19, wherein the casting is investment casting.

21. The stainless steel sledrunner of claim 17, wherein the stainless steel sledrunner is formed by forging.

22. The stainless steel sledrunner of claim 17, wherein the stainless steel sledrunner is formed by stamping.

23. A stainless steel beader comprising:

a first stainless steel element having a first surface, the first surface having a first contour configured to impart a first form to an unfinished mortar joint; and

a second stainless steel element adjacent the first stainless steel element and having a second surface, the second surface having a second contour configured to impart a second form to the unfinished mortar joint.

24. The stainless steel beader of claim 23, wherein the stainless steel beader is formed by casting.

25. The stainless steel beader of claim 23, wherein the casting is investment casting.

26. The stainless steel beader of claim 23, wherein the stainless steel beader is formed by forging.

27. The stainless steel beader of claim 23, wherein the stainless steel beader is formed by stamping.

28. The stainless steel beader of claim 23, wherein the first element has a first shape, and the second element has a second shape that is different than the first shape.

29. The stainless steel beader of claim 23, wherein the first contour is different than the second contour.

30. The stainless steel beader of claim 23, wherein the first contour is convex.

31. The stainless steel beader of claim 23, further comprising a stainless steel connecting element extending between the first stainless steel element and the second stainless steel element.

32. The stainless steel beader of claim 31, wherein the connecting element is formed with the first stainless steel element and the second stainless steel element.

33. A method for manufacturing a mortar joint finishing tool, comprising casting a unitary body of stainless steel that comprises a first mortar-contacting element having a first mortar-contacting surface adjacent a second mortar-contacting element having a second mortar-contacting surface.

34. The method of claim 33, wherein the casting is investment casting.