[TheForge] Re: TheForge digest, Vol 1 #118 - 11 msgs

[theforge@mailman.qth.net]

In a message dated 2/3/2002 7:34:31 AM Pacific Standard Time, Ralph Sproul 
writes:

<<   Don,  I wanted to ask where the parts were that you had such a hard
 time drilling out?>>
         
I found the 1" and 1-1/4" frames impossible to drill. You can get in about 
1/4" from any side but the interior is like carbide. Apparently, the original 
blacksmiths had similar problems. Almost all fastenings are done by drilling 
in about 1/4", inserting a rivet with a grooved ring and then they are seated 
with a hollow punch. When I had to replace a tenon in this stuff I just 
ground out a channel of about 90 degrees of a circle, with a 1/4" thick right 
angle grinder blade, and welded in a 1/4 rod.

<<Also you mentioned using the pure iron on the project.  What did you
 do to fasten it to the frame? was everything riveted, collared, bolted and
 mechanically fastened? >>

Au contraire, mon ami. Much of the serious damage was in the scrolled ends 
which were originally done by thinning 1/4 x 3/4 to a sharp edge and wrapping 
tightly about 2-1/2 times. (I suspect a strong German influence in this 
style). The deterioratin occurs here because the underside of a scroll with 
the curve up, provides a spot for a single drop of water to hang. After 150 
or so years of acid rain drops hanging in that spot the metal becomes 
completely eaten through. Even the best wrought iron will fall like an 
encroaching cancer to this constant moisture. 

In an effort to salvalge as much original material as possible, the 
deteriorated scroll ends and etc., were cut off with a Sawzall and new scroll 
ends mig welded on. All were beveled appropriately. I used my little Hobart 
Handler with flux core wire which I could use without the end shield. With 
just the wire I can get into spaces as small as an inch...maybe less. Then 
the weld area was filed smooth with a half round file. A most tedious work 
but the results were good. 

With some fastenings there was just a nub end of a tenon left to attach to, 
so I chamfered the hole in the piece being replaced, put it in place and mig 
welded into the hole to the tenon and built up a domed disc of weld. Again 
with the low amp Hobart Handler. Once that was peined slightly it looks ever 
so much like a nice tight rivet. 

Don Plummer
Plummer Design Works
Phoenixville, PA
www.plummerdesignworks.com