New Roof Crest: The new cresting was formed in 10′ sections. They were formed in two 3 dimensional faces and soldered together at the entire perimeter.
New roof cresting progress: First round of stamping new roof cresting
New roof cresting progress: Second round of stamping and partial trimming
Closeup detail of finished roof crest
The roof cresting is attached to the ridge covers that we brake formed out of galvanized steel
The original finial was rotted very thin and had numerous patches of tin, caulk, even spray foam!
Where possible original sections are stripped and used to make hammerforms.
A couple of hammerforms and the new components that are made with them
Sometimes we use both male and female hammerforms. Repousse components are hammered out from the behind (female form) then details are chased back in from the front (male form).
This component was too thin and damaged to make a hammerform from so we sculpted a new form
Boxed it up …
Poured a new hammerform (as seen on the top left). This picture shows just some of the modified and custom made tooling for this job
The large “Water Leaf” urn section coming together
Completed, fully soldered zinc finial. All components of this finished finial are hand formed “repousse” and soldered together into one unit. (Repousse is the technique of shaping & hammering malleable metal from the reverse side)
New finial in its place at the end of the new roof cresting
Previous misguided attempts of scroll repairs. We hand forged proper reproductions
This picture shows previous inadequate attempts to fix the scrolls. They are not true to form. They are bolted on. The pickets are arc welded. The original tenons are broken or missing. Most of the mortise holes are split from rust. Previous repairs to the splits were done with improper materials and methods.
The previous repairs have been removed and all signs of that work has been restored properly. The restoration entailed hand forging new scrolls to match originals. These are forge welded and tapered. Each unit consists of 2 scrolls, tapered at the ends to fit with the next sets of scrolls. Top rail has been repaired. We reforged new tenons on the original pickets. In the original design, the tenons on the pickets passed thru the scroll & top rail and were hot forged down to hold the entire assembly together. (In this picture, the tenons have not been forged down yet.)
We smoothed the scroll. Gouged metal on both the rail and scroll have been restored. Forged and welded a new tail. Visible is the picket with the end restored with the new tenon.
Original scroll that had previous repairs. The tail has been burned off. The scroll and picket were welded to the top rail. The scroll is deformed.
New scrolls are hand reproduced using the same blacksmithing and “forge welding” methods as the 1760’s originals.
The restoration of 10 bronze kalamein night doors and frames required the removal of any damaged cladding, repairing of deteriorated wood substrate (replacing as needed), reinstalling cladding (replacing as needed), and repairing the hardware (replacing as needed).
Job included repairing the doors by patching holes, rebuilding (and in some cases fabricating new) hardware, making new custom bronze door pulls and rosettes, making a new cast bronze grill to match the original, and refinishing.