I have been working on some plant stands for a church in the area.  They are getting close to the final assembly and I thought you might enjoy an advanced look!

The two stands feature forged bronze rings as well as bronze sides at the top.  They also include large rivets at the base.  This stand is temporarily pinned together to check for fit-up.

Prior to forging, the bronze pieces were pre-bent. I experimented with test pieces in iron to determine the proper radius to pre-bend the stock so the bronze rings came out as planned.

Here, I am using one of my favorite tools, a old 3-headed drill press made by Buffalo Forge to drill mounting holes in the rings.

Decorative Beam Brackets

You see them often in cabins and log homes--those black iron straps used to bolt wood timbers together.  I have often thought that there is a way to make them decorative as well as functional, thus allowing them to contribute to the home's overall design.

Five years ago I got my chance.  The owner of a remodeling company in Minneapolis needed some beam brackets for load-bearing timers on the second floor of a lake home he was building. He recognized that people would be seeing the brackets up close as the timers formed an arch at the top of the stairs of the loft.  He provided drawings defining how the brackets had to work.  I added design elements including layers of metal, curved ends and diamond headed bolts. I shipped the completed the brackets to the site.  While I got a note from the builder with his payment that the brackets worked fine, he provided no photos or other info about the install.  Well, this summer I finally got to see how the installed brackets turned out. I stopped in after doing some canoeing in western Wisconsin near this home. Here are some photos of the home.  

Do you have a project that calls for beam brackets?  Please give me a call at Island City Forge to discuss how we can make them fit with your design scheme.

 

St. Matthias Votive Candle Stand

In 2005, Minocqua's St. Matthias Episcopal Church constructed a new, larger worship space adjacent to the original edifice.  In 2012, the parish paid off the mortgage.  Island City Forge was commissioned to design several liturgical items for the new space.  The votive candle stand is the first piece to be completed.

 

 

 

 St. Matthias Pastor, Edgar Wallace and office manager Michael are happy to see the new votive candle stand installed in a cove in the church. 

 

 

The candle stand compliments the new worship space which was designed in the Arts and Crafts style, similar to the original edifice.  The candle stand incorporates large rivets and forge-textured bronze in the sides of the top tray and in the cross.

 

 

 

 

 

 

The crucifix at the center of the stand is made of layers of forged steel and bronze, held together with rivets

 

 

Back in the shop during construction, the partially completed candle stand is assembled on the main bench.  Here, I am working with a wood mock-up of the crucifix to properly size the elements.

2013 WI State High School X-C Team Persuit Trophies

The Wisconsin High School Cross Country Ski Championship races were held in Rhinelander this year.  Island City Forge was commissioned to design and create the trophies.  Knowing that some of the teams which have won in the past already have awards created by ICF, this years models are similar, but not identical to ones I made in 2007 and 2008.

The top three teams in both the boys and girls categories received trophies.  Here, the trophy models pose for one last group photo in the shop.

After assembly, each metal figurine was heated in the forge to approximately 1000 F.  Allowing them to cool from an orange heat to room temperature imparts a uniformly dark finish.  Think of the forge as a tanning booth for the trophy models.

Here are the forged parts before cutting, drilling, assembly and mounting on to the birch wood blocks.

Sunflower Andirons

 

These large andirons were designed and forged for a client who had just added a porch and a large outdoor fireplace to a barn on his weekend getaway farm. Each andiron stands over three feet tall and features a large sunflower and leaves. The andirons consist of five layers of metal, held together with large rivets.

This project was sucessful do to several factors: The client was very engaged in the design process. I created an initial design rendered in a 3-D sketch with numerous variations. He chose parts from several for the final design. Then, to satisfy his desire that his andirons were truly one-of-a-kind, I added an additional layer to the left andiron which supports a sunflower bud.  Lastly, the client builds large, hot fires in the fireplace. Both the andirons and massive firegrate are built to last for generations.

 

Firplace tools

This set of fireplace tools was designed in a modern sytle.  With its clean sculptural lines, it is as attractive as it is functional.  The set features contrasting metal textures and a bronze collar on each handle.  The broom is hand-tied by another local artisan.  This set is one of two that have been recently completed and both are availble for purchase.  Credit for these great photos goes to Gabe Korinek.

Candelabras

Here is a set of candelabras, just completed. The clean lines and brushed finish show the kind of refined work that is possible at Island City Forge.  The photo credits go to Gabe Korinek.  Gabe spent a couple of days composing these shots, working with natural and artificial lighting to create these great photos.  Thank you, Gabe.

Bronze handrail

This railing was recently forged for a cabin retreat in western Wisconsin. The handrail and support brackets were frorged from bronze, resulting in an attractive look that will never need refinishing. The uprights, cut from structural steel, will be encouraged to rust. After about a year, they will be oiled, stopping the rust and creating a rich, dark texture. The contrasts in metals and textures are right at home in this rustic setting.

Counter brackets

These large brackets support a polished concrete countertop. The brackets, are over 3 feet tall and feature large diamond shaped rivets.

Cattail and Blue Heron Railing in Saint Germain, Wisconsin

This wood and iron railing portrays the beauty of the blue heron in her natural setting. Forged mild steel.

 

Terrace Railings in Chicago

This elegant and curved railing adorns a large slate terrace for a residence near Chicago. It features broad sweeping curves and a verdigris finish. With a combined length of over 160 lineal feet, it is Island City Forge's largest project. 

I was one of a team of three blacksmiths who created the railing. Each of us built major sections of the railing in our own shops, then brought them together for bending and finishing. The project was coordinated by Bob Walsh, artist blacksmith, who brought in two additional people for the installation.

Thanks to the precise initial measurements at the site and the quality of each smith's work, the railing fit perfectly.

The railing was sandblasted and then hot-dipped galvanized prior to painting to assure the long-term durability of the finish.

Each railing section was curved after it was assembled to match its location on the terrace.

Modern Railing in Sudbury, Massachusetts

Railing with continuous handrail completes a modern residence with a central stair tower. It spans two and one half stories. Won the Luxury Living Award along with chief architect, Chris Walsh of Framingham, Massachusetts.  Mild steel with stainless steel cable and connectors.

Northwoods Railing in Minocqua, Wisconsin

This railing is a successful blending of cedar and steel in a major remodeling of a residence in Minocqua. Views from the Great Room look out over Lake Minocqua.

The intent of the design was to add a focal point by incorporating natural curving forms for a space that is defined by straight lines and right-angles. The railing also meets the new requirements in the building code that specifies a maximum "pass-through" of four inches for railings.



Classic Railing in New York City

This railing defines the street entrance to an architect's office in New York City. It features spear-shaped finials on top of straight pickets to create a classic look.

Modern fabrication techniques were used to complete this project. For example, the major panel elements in the two window grilles were created using the water-jet cutting process.

Fireplace Screen in a Storybook Style

This screen was originally designed to be placed in front of a rectangular fireplace in a ranch-styled home. The curves of the top of the frame and the plant elements work to add some curved shapes into an otherwise rectilinear-shaped room. Note that the lower center of the screen is open to allow for an unobstructed view of the fire.

Oak Tree Fireplace Tools

The clients desired a set of fireplace tools that mimics shapes in the stand of oaks outside their new home in Grafton, Wisconsin.With tools in the shape of branches, the set features oak leaves, acorns and a metal base in the shape of a slab of oak trunk.

The leaves are cut from flat sheet. Then the veins are chisled in.  Next, the stem is rolled and the body is shaped while hot. Fortunately, there is an abundant supply of oak leaves in the woods near Island City Forge to use as models.