Shrinking into Curves

Just a fast visual posting today - on the Graham House door panel project: Where does all that metal go?


The first drawing is the concept layout. You will notice that I do not 'forge to a blue print'. The door with its glass inset panel defines the framework for the finished piece. I do keep to the general outline of my concept drawing, but as the work progresses, individual elements may vary as the complex curves are forged.

The second image shows the two main support elements, ready for the final forging into two wide arcs ending in spirals and reversal curves. Each piece started as a length of 3/16 X 2 inch flat stock. The ends have been pointed, upset and flattened, then drawn to a long taper. This results in a flat disk at 90 degrees to the flat side of the centre bar, with a long diagonal line leading to it. Then the central portion of each was had pilot holes drilled, which were drifted open to accept the roughly 1 inch diameter tubes that are the main elements of the panel.
Check the lengths at this point. The flat bar started as roughly 3 and 4 foot long. You can see that the tapering step has lengthened these to about 4 and 5 1/2 feet.

The last image shows the finished support elements. You can see that all that length very quickly disappears once a few curves are created. The door measurements can be seen drawn on the layout table, this is a standard 32 inch wide. The faint grid lines have 6 inch spacing. You can also see my concept design drawn out in chalk on the layout table. Compare the final result with the design, and you will see that although these are close - they are not identical. The spirit of the intended design remains.

Next step is to alter the round holes to distorted ovals. This is required to allow all the tubes to pass through the curved support elements. Once this is done, the lower finals (made separately) will be welded in place, then ground to make that addition invisible. (Ah - Thats how he did it!). Then the tube elements are welded securely to the supports (from the back side where it does not show). Last is fitting the upper frames for the glass disks into place.

(Stay tuned)