[TheForge] instructions to make a Angle Iron Feathers

Sun Oct 13 19:41:21 2002

Thank-you, Larry-I think we'll enjoy this ;-)

Phlip

----- Original Message -----
From: "Larry Zoeller" <[email protected]>
To: <[email protected]>
Sent: Sunday, October 13, 2002 4:28 PM
Subject: [TheForge] instructions to make a Angle Iron Feathers


> To All,
> These are the instructions that Rod Pickett gave.
>
> 1. Cut the angle iron approximately 24" long to give you a handle.
>
> 2. Heat about 10" of angle to an orange heat.
>
> 3. Lightly hammer the web, driving the flanges out, flattening the angle.
> Take care to not overly flatten the web as this will become your quill and
> shaft.  This may be done on a power hammer or by hand.
>
> 4. Taking care not to damage the shaft, smooth out both edges.
>
> 5. Heat the end of the bar and taper the shaft to flat for about 1 1/2".
>
> 6. Using as few heats as necessary and working over the edge of the anvil,
> draw out the flanges to a blunt knife edge.
>
> 7. When it's cool, use a soap stone or silver pencil to sketch the rough
> feather shape on your blank.  Using a notcher, band saw, or hot cutting
with
> a chisel, rough cut the feather shape leaving about 2" of quill on the
> bottom end.
>
> 8. Rough grind the profile and use your grinder to refine the feather
edges.
> I use an angle grinder with a stone wheel, but this could be done by
forging
> with a flatter if you want to use a lot of heats.
>
> 9. I then use a standing disc (60 grit) on my angle grinder and refine the
> feather, removing hammer and grinder marks and giving the shaft a radius
> profile.  At this point I blunt the edges and clean the back.  For my
> purposes, this is a single faced ornament.  If you are going to show both
> sides, you'll need to refine the back side as well.
>
> 10. Use a sharpie and mark the feather details.  Some will be cut and some
> will be carved.  It's my opinion when designing that odd numbers look more
> natural, so I tend to use an odd number of cuts on the feather.  Avoid too
> balanced of symmetry.
>
> 11. I used the band saw to rough cut the splits between the feather barbs.
>
> 12. Using the angle grinder with a sanding disc (approx. 60 grit), clean
the
> edges of the band saw cuts and start carving some of the feather barb
> details.  Again, if you would rather, these last two steps could be done
> with a hot cut chisel.
>
> 13. Using a very sharp-edged sanding disc, continue to carve more feather
> barb details.
>
> 14. Either use a worn disc or a finer grit to polish out sanding marks and
> smooth the shaft/quill.  Take care not to sand out the carved details.
>
> 15. Using small files, remove burrs and refine the carved details.
>
> ----- Original Message -----
> From: "Phlip" <[email protected]>
> To: <[email protected]>
> Sent: Sunday, October 13, 2002 10:29 AM
> Subject: Re: [TheForge] Angle Iron Feathers
>
>
> > OK, I copied the pic and I'm sending it to you privately. It really is
> worth
> > seeing.
> >
> > So, are we going to get a rundown of the technique?
> >
> > Phlip
> >
> >
> >
> > ----- Original Message -----
> > From: "Bob Rackers" <[email protected]>
> > To: <[email protected]>
> > Sent: Sunday, October 13, 2002 11:17 AM
> > Subject: RE: [TheForge] Angle Iron Feathers
> >
> >
> > > I can't even connect to http://www.geocities.com/
> > > Running a trace gives me a "Destination host unreachable" message.
> > >
> > > Bob
> > >
> > > -----Original Message-----
> > > From: [email protected]
> > > [mailto:[email protected]]On Behalf Of Dave Brown
> > > Sent: Sunday, October 13, 2002 10:03 AM
> > > To: [email protected]
> > > Subject: Re: [TheForge] Angle Iron Feathers
> > >
> > >
> > > John,
> > >
> > > It should work fine without any special actions.  Here's the link
again
> > > (copied from my Netscape location field:
> > >
> > > http://www.geocities.com/zoellerforge/feathers.html
> > >
> > > Try it again.  It may have just been something in the way your e-mail
> > > reader displayed it.  Make sure you get everything from the http: part
> > > through the end of the html part.
> > >
> > > Good luck,
> > > Dave Brown
> > >
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