One of the main challenges of cutting an arch is figuring out the dimensions and glue angle of straight boards from which an arch can be cut. Fortunately, this time around I’m using Sketchup. As you can see in the picture it is pretty easy to figure these out, although I’m still searching for a formula to calculate the dimensions. The vertical angle is 15 degrees. I drew a line intersecting the bottom of the middle of the arch with the bottom of the right side. I then made a ...
First… after seeing Trifern’s secrets on dyeing I wonder how a door would look? Guess I’ll have to give it a try. Anyway, here’s the gate with several coats of outdoor oil over some redwood stain. The colors in the photo are pretty accurate. The top picture gives a good comparison of the treated and untreated copper panel. Once the gate is hung I will post a final blog on this series with photos and some specifications and tips I learned on this project. An...
Nothing real exciting at this point. Just wanted to have a complete blog on this project. I used the Turnlock System and Circle Jig by Milescraft to cut the arch in the panel. I noticed a nice review was posted by Teenagewoodworker on this jig and plan to my experience and thoughts when I get a chance. The bent laminations fit nicely and the whole thing easily went together, which is a pleasant change from my normal routine. I installed one side of the stays and left the othe...
There are a number of ways to hold the panel in place. You could cut a rabbet on the inside edge, or you could cut a groove on the inside of the stiles and rails like a cabinet door panel. I chose to stick with the method David Marks used, panel stays. Yet once again, there is an arch to deal with. This time I thought I would just use the top rail as a bending template for a bent lamination to ensure a good fit. The plan was to resaw thin strips 2” wide and just long enough to fit ...
Here’s my first attempt at the hot patina process. All but one of the chemicals arrived from ArtChemicals, the Cupric Nitrate being on back order. I decided I couldn’t wait and pressed on anyway. I printed labels so I could keep better track of the chemical blends and colors each was supposed to produce. I learned two things right away. The first is this is a complicated process. The second is you really can’t mess it up. I used the method demonstrated by David Marks ...
Ever since I saw David Marks’ Japanese Garden gate I was intrigued. I think it is the idea of working with wood, metal, chemicals, heat, and a creative process that caught my attention. It also helps to end up with something functional that is, hopefully, attractive to boot. So far my research has included re-reading David Marks DIY project page on this and his other patina projects, viewing Ron Young’s patina DVDs, looking at the Art Chemicals webpage, and searching the ...
Finished! Well it’s been a long journey and it did not end without one extra push. I finished installing the copper handles Monday by 11:30. There was a couple of scratches but I was certain I could buff them out. This is a skill that goes with the territory. I worked on the finish for the next six hours and I could not get the finish to blend. How to Remove a Scratch- After exhausting all other options this is what I resorted to today: Yes you are seeing it correctly...
Another Milestone I am pretty excited to share with you guys today’s progress. I got all of the handle pieces finished! Next I have some touch up on the doors and the final install. I am sure I will have a full day of technical sweating. I had to brush the pieces again on the wire wheel to brighten the finish. I then hung them from the ceiling and wiped them down thoroughly with acetone. This strips any oil from the surface. I sprayed them with an acrylic resin lacquer by Sh...
Getting Closer… Well guys I can hardly stand it! I am getting so close to done on this project and yet there is so much to do. I just want to go home and be with my wife and my dogs so bad. This job has been a nail biter every step of the way. The more I get done, the more work I have at risk if I should screw up. A mistake could cost the equivalent of a good used car – NO KIDDING. If you want to do high-end work, the risk is high too. That is one factor most don’t...
Over the past few years, I have had the chance to build my own door handles out of copper for several commissioned art-furniture pieces. This is something I enjoy doing, and it gives my work another niche to offer. I would not say that I am a coppersmith, as there is a lot that I don’t know about the process. I am almost completely self-taught, so there is bound to be a lot I haven’t learned yet. I bought two old reprinted books on the subject of coppersmithing, and I think ...
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