| The overall project consists of three
              separate elements : 
 
              
                
                  | Phase 1 -
                          Fence ExtensionMay 2011
 
                      
                        
                          |  | The customers had a board and batten
                              fence around the front and down the
                              driveway on their property. With a new
                              (young and energetic!) dog, they were
                              concerned that he would be able to jump
                              the existing fence. There are posts set
                              roughly every 8 feet, the fence boards are
                              cut on a sweeping curve in a sideways D
                              shape. The difference between the peaks in
                              the middle and the level at the posts is
                              about 12 inches. Images by Karen
                                Peterson |  |  
                      
                        
                          |  |  As a an alternative to replacing all the
                              fence boards, they asked me if I could
                              work up a decorative metal extension in
                              increase the effective 'blocking' height
                              of the fence. My solution was to use a
                              horizontal line of 1 inch diameter pipe,
                              held above the existing fence top by a set
                              of decorative brackets. The intent is to
                              raise the line of the fence by 4 - 6 inch
                              at its highest point (so 16 - 18 inches
                              above the post area).To fill the gap around the posts will
                              require placing a total of four brackets
                              (using a roughly 6 inch square grid as the
                              spacing guide). The pipe will consist of a
                              number of 8 foot pieces, with a small gap
                              just above the individual posts. This
                              allows for any sway to the fence line. It
                              will also make installation a lot easier,
                              even allowing to raise the height of the
                              pipe line should that prove necessary.
 The individual brackets will be forged to
                              individual organic curves. The leaves hang
                              down below the top line, helping to block
                              the gap above the posts. I also wanted to
                              enhance the organic feel of the brackets.
                              For that reason I forged a separate
                              smaller 'tail' which will be welded to the
                              main structural part of each bracket.
 To ensure there would be enough physical
                              strength to the support, I chose 1 1/2
                              wide by 1/4 inch thick flat stock. The
                              tails are forged from 3/4 or 1 inch wide
                              by 1/4 (roughly half of each width).
 |  |  
                      
                        
                          |  |  |  |  
                          | Support elements before
                              installation - total 62. | View from the sidewalk,
                              up the driveway. | Closer view, the rail
                              hangs behind the fence line. |  |  
                  | Phase 2
                          - Porch SupportsDecember 2011
 
                      
                        
                          |  | The next commission was for a replacement
                              set of supports under the front porch. The house is late 1800's, a nice 'short
                              two story' brick, what could be considered
                              an affluent farm house of the period. The
                              front porch covers the entry for the
                              original entry door, with a small balcony
                              above off the master bedroom. The original
                              sculpted wooden pillars have rotted out.
                              Part of the project has included replacing
                              some of the timber support beams
                              underneath.
 The image to the left shows the original
                              wooden porch structure.The image to the right has been altered
                              via Photoshop to remove the supports and
                              wooden picket railing. This as a starting
                              point to further design work.
 |  |  
                          |  | As with any project of this nature, there
                            is a structural component, plus an artistic
                            consideration. The first possibility was to
                            continue working in that theme - a design
                            based on the natural lines of vines with
                            large leaf end terminals. As usual, I sat
                            down with the clients and had them pour over
                            a number of book collections of contemporary
                            work by other artisan smiths. We marked
                            things they liked, with me making notes on
                            their specific comments. Later, I took a
                            more careful look at those pieces, narrowing
                            down the general outlines from all the
                            specific illustrations. From this I was able to generate a number of
                            rough layouts. One specific structural
                            requirement was going to come to dominate
                            the possibilities - that there had to be a
                            strong vertical line of metal to support the
                            weight of the heavy porch roof and its upper
                            deck. In most cases, this reduced the visual
                            aspect of the potential designs to look too
                            much like 'a beam with stuff stuck on to
                            it'.
 
 
 |  |  
                          | 
 Runnels of slag - Slag
                                Pit Smelt 1 October 2011 | In the end, I was struck by the potential
                            from something else entirely: 
 Neil has become my enthusiastic right hand
                            for the ongoing experimental iron smelts
                            here in Wareham. The massive slag block
                            produced in our 'slag pit' smelt in October
                            was composed of individual runnels of slag,
                            running downwards through a bundle of willow
                            sticks. Even at the time, we both remarked
                            on the artistic possibilities.
 
 So I was struck by a potential design -
                            using a bundle of individual tubes, instead
                            of one major structural elements. In fact, a
                            bundle of smaller tubes would be *stronger*,
                            with the many side wall cross sections
                            combining to the load carrying capability.
                            Inspired by the folding and bulging of the
                            slag, individual tubes could be partially
                            flattened, twisted, folded or surface
                            deformed. The bundle would be both welded
                            and then wrapped with tendrils of round rod.
                            This would both massively reinforce the
                            welds, but also add an additional decorative
                            feature.
 
 Of course - I couldn't really draw this
                            concept effectively!
 Faster to make a sample piece...
 At the right is the original sample,
                              composed of a total of five individual
                              pieces of pipe. The central core is larger
                              diameter (roughly 1 1/4 OD) and the outer
                              pieces of smaller (thus more flexible!)
                              pipe (roughly 7/8 OD). The sample is about
                              two feet long, and has tendril wraps of
                              3/8 round at either end.  A number of
                              different forging techniques have been
                              used on the individual pieces. The
                              competed sample bundle is roughly four
                              inches wide.  |  |  
                          |  | At this point, I played some hoo-doo with
                            Photoshop. - First I photographed the sample piece from
                            a number of different sides.
 - I then spliced the images together to
                            create an impression of what a full sized
                            support would look like.
 - I then scaled that image to fit the
                            proportions of the modified image of the
                            front of the house (with the existing
                            structure removed digitally).
 
 Scaled from the four inch width, the bundle
                            just looked too small in proportion to the
                            rest of the structure. Next I played some
                            games with scale - and the result is seen to
                            the left. Here you see the bundle increased
                            in size so it 'looks right'. Measuring from
                            the known dimensions, the bundles should be
                            closer to six inches wide.  (The total
                            height of each is roughly 8 1/2 feet.)
 To the right is my design drawing for the
                            base section of the proposed supports.
 
 A basic principle to follow is 'over
                            engineer everything'. The centre unit in
                            each of the bundles was a straight length of
                            2 1/2 ID schedule 80 mild steel pipe, with
                            roughly 1/4 inch thick side walls, which
                            would carry the actual load of the balcony.
                            The individual lengths of pipe that composed
                            the decorative elements were individually
                            forged to flattened segments, twisted, then
                            MIG welded to the central cores. Tendril
                            wraps of 1/2 round rod covered over the
                            welded areas, as well as contributing to the
                            overall effect.
 
 |  |  
                      
                        
                          |  |  |  |  |  
                          | Overall view of the
                              Pillars | Looking North on porch | Looking South, back
                              towards fence | Detail of Pillar |  
                          |  |  |  |  |  
                          | Top of North pillar - to
                              West | North pillar, from porch | Top of South pillar - to
                              West | South pillar, from porch |  |  
                  | Phase 3 -
                          Balcony RailingFall 2012 - Summer 2013
 
 
 
                      
                        
                          |  | The final component of this project was a
                            replacement for the original wooden picket
                            balcony railing. The small balcony over the
                            porch roof was accessed from a door off the
                            bed room, and facing on to a busy street it
                            was rarely used. The home owners were both
                            middle aged adults, and so provisions for
                            children's safety was not a consideration. 
 As is usual, I had generated several rough
                            concepts, working inside the kind of organic
                            lines used for other portions of the
                            designs. The original concept was to make
                            the railing elements as a set of sweeping
                            curves.
 
 |  
                          |  | The clients had been familiar
                            with my past work, especially the concepts
                            behind 'Paris
                              Metro', which had involved layering
                            structural steel profiles modified by hand
                            forging, which where cut apart into
                            individual lines at the ends. 
 Of course, what looks good on a drawing may
                            prove overly complex - and actually
                            difficult to fabricate when considered as
                            forming steps.
 
 
 |  
                          |  
 | In the end it was decided to
                            use a simpler configuration for the
                            individual railing pieces, flaring the ends
                            but otherwise cut segments. The uprights
                            used a core of 2 " heavy walled tube as a
                            core, with additional elements of slightly
                            flattened angle laid inside channel welded
                            to the outside. Cut at the top ends, the
                            flat lines were extended to tendril wrap
                            around the rail pieces, with additional
                            wraps of 3/8 and 1/2 " solid. 
 The metalwork was finished
                              with hot galvanized underneath dark brown
                              enamel paint.
 
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                          |  
 |  
 |  |  Further detailed in Blog
                posts:Sunday, March 06, 2011
 Peterson Fence Project
 Thursday, May 05, 2011
 Peterson Fence - Installed
 Saturday, November 26, 2011
 Where DO Ideas Come From (3) - Peterson
                  House
 Saturday, November 26, 2011
 Forging the BIG Time (again!)
 Saturday, December 24, 2011
 Peterson House - Front Supports : INSTALLED
 Saturday, July 6, 2013
 Peterson
                  Balcony Railing
 
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