We've been running a thread on how best to fix the clapper from the bronze bell (c. 1870) at my church. The shaft of the clapper had broken through.

I appreciate the help of all the metal-workers of various stripes who contributed. We printed off the entire thread, ruminated over the insights, and then gave it to the other clapper-retriever. He sent a message as follows:
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Clapper is actually forged steel...determined by "spark testing". My machinist recommended welding. I told him this was God's bell and that clapper failure would result in a blight of locusts. He stood his ground, so I told him to go ahead.

I had my tool designer (a retired metals systems designer from
Honeywell) look at it after the repair had been competed. He said that it should be fine. He offered an alternative of tapping 3/4 inches into the end of each section, inserting a 4140 threaded stud (Rockwell C 35-38) and running a shallow bead around the joint.

It seems that any failure in the clapper would result in a repeat of finding the clapper laying underneath the bell. In that event we could try the threaded insert alternative or try to find a blacksmith with the necessary knowledge to forge weld the pieces.

I did a search for bell/clapper info on the net and came up with some insight on tone quality. The flattening on the clapper contact surface is a bad thing tonewise, so I had them rotate the pieces 90° to put the proper surfaces in contact with the bell. We also installed a bronze bushing in the eye of the clapper and replaced the bolt and nut.
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This Friday evening, the clapper goes back into the bell. I have a crucial role - feeding the guys afterward. I will also be on the ground, listening for a beautiful new tone from the restored bell.

What is a bushing, anyway?