Here is a photo of a restoration that we completed on a historic Lenox Hill residence. This project included the restoration and refinishing of the location's original 120 year old exterior fencing, newel posts, and gates. To learn more about our restoration process, please visit our "about" page.
Forged Monel Gate Hardware Custom Made for a Historic Residence
Once the design process is complete and the drawings have been approved by the client, the fabrication process can begin in our studio.
The first step is creating a cut list of the metal stock that will be used in the construction of the pergola. Once the pieces are cut and shaped, they are laid out according to the shop drawings and checked to ensure that all dimensions are correct.
When fabricating a project where there will be more than 1 of a piece, we will create a jig that can speed up the process. A jig is a large brace that keeps a welding project stable in the face of pressure, heat, motion, and force. A quality jig will streamline welding work by keeping parts together in a vice grip. This ensures uniformity throughout the construction.
The pieces are then prepped, and tack welded. Before fully welding the trusses together, they will once more have the dimensions checked for accuracy.
After the welding is complete, and depending on the level of required finish, the welds will be ground and sanded to a specific standard set by our shop.
Shown here, is one of two decorative ginkgo trusses complete and ready to be painted. This pergola will be finished with a flame spray zinc metallizer to prevent rust, and then powder coated in the client’s color of choice. This combination creates a finish that will last for decades.
Here is the completed top of the pergola mocked up at our shop to be receive final approval before it’s sent to be metalized and painted. Once we receive the powder coated pieces, our last step will be installation by our talented crew. Please keep an eye out for Building a Custom Pergola PTIII; installation.
Our beautifully designed and executed ginkgo-leaf inspired pergola is now in its home. This striking architectural structure now covers our client's outdoor terrace and will surely be a topic of conversation during their next gathering.
Please keep an eye out for part II of our next case study; "Building a Custom Pergola-PT II of III: the fabrication process"
Here are some images of a fun interior project we completed for a local resident. Our client wanted to embellish his wine cellar door with a custom grapevine inspired panel. The end result was quite beautiful!
What goes into creating a one of a kind custom design?
As a group of skilled artisans, we love using our artistic skills to create unique metalwork. When we received a request to build a custom decorative pergola, our designer Rachel, went right to work developing a design that would fit the client's tastes while at the same time addressing the many technical issues involved. This is a multi-step process which involves meeting with prospective clients, surveying the work site, conceptualizing and creating design sketches for approval, and finally, the creation of accurate shop drawings used for fabrication.
Our company was approached by The National Parks Service with the request to repair and restore some stair components located inside of Fire Island's 160 year old historic fire house.
Here is an image of some hand hammered copper switch-plates made by one of our craftspeople for his home. These pieces were inspired by some hand forged iron switch plates made by the renowned craftsman: Samuel Yellin. They have a natural fire-scale patina.
We are currently finishing up on restoring the entry gate for the historical; Woodland Cemetery located in Bellport, N.Y. Completed in 1869, the cemetery has a memorial statue commemorating some of the local residents who fought and died during the Civil War. In addition to fully restoring the original ironwork, we designed and built a beautiful over-gate which prominently displays the cemetery's name. Below are some images of the process. Please keep a lookout for a full case study on this project coming soon to our website.
Here is a short video of 2 our craftspeople creating a custom texture on 2"X 6" Aluminum bar. We did this by using a custom die made in house.