English Style Garden Gate

Well here we go. I start with my client approved design, measurements from the location and a blank floor as my canvas.

I make a full scale drawing of the design to guide me as I forge and weld. It also allows me to catch design mistakes before I make them on the real thing. The Devil is in the details.

  

I like to have the client stop by the studio to see the full scale drawing and to get a feel for the scale and proportion of the gate. It also gives me an opportunity to discuss material sizes and any changes I might need to make and get their approval.

As I make progress on the framework, I mentally start working on the forged details. 

 

The flowers will be made of 16 gage mild steel. I rough them out with my band saw and grid them to finished shape.

I had to make a bottom die to crease the front of the flower.

Then I had to make another bottom die to crease the back of the flower.

Now the flower goes in the forge. Just looking at this gets me excited.

Again I stoped to make more tooling. This tooling pushes the flower into into its basic shape.

I know what you’re thinking. Does it really take all this effort just to make one flower? No, it takes more. More hammering, more shaping, and more fun.

Forged Flower

I made a forged flower for my wife for Valentines Day. Without her support and encouragement, none of this would have been possible. Thanks Joyce, you're the best!

Forged Letter Opener

To begin the letter opener process I cut off 7 1/2" of 1/4" mild steel square stock.

Then I take it to the flypress to emboss lines that will be twisted.

Here's what the part looks like after embossing lines with the flypress.

Now the part is put in the gas forge and heated.

This is what the metal looks like as I start forging the blade.

After several reheats in the forge and a lot of hammering the blade is finished.

Then I clamp the part in a vice and heat the embossed lines and twist them.

I forge the handel end to a point and then I use this tool to create square beads between the twists.

After all the twisting and beading the part needs to be straightened so I use a wood block and mallet so I don't damage the sruface.

To finish the letter opner I use a patina to darken the metal then dip it in hot bees wax.

I know, I know, hurry up and finish allready. Well here it is! Like fine wine, good things take time.

This is a wedding gift for some friends who wrote letters to one another while courting.