Historic Restoration of Wrought Iron Handrails, circa 1760s, at the Schuyler Mansion

Click photo to see job progress

Original railing before restoration

Closeup of deterioration

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.

 

 

Closeup of 4 piece joint

 

 

 

 

 

 

Restored Railing

Restored Entrance

 

 

 

 

 

 

 

 

Hand Forged Iron Ladder with a Hammer Textured Finish

Hand forged ladder with hammer textured finish. The rungs are twisted at the center. The connections at the rungs to side rails are hand forged mortise and tenons with the ends of the tenons peened over and left visible. The finish is highlighted with an abrasive pad to show off the textures and details.

Hand forged ladder with hammer textured finish. The rungs are twisted at the center. The connections at the rungs to side rails are hand forged mortise and tenons with the ends of the tenons peened over and left visible. The finish is highlighted with an abrasive pad to show off the textures and details.

Custom Bronze Grill with Hand Forged, Fabricated, and Repousse Components

 

Click photo to see job progress

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Repoussed leaves start off as flat pieces of bronze, then hand hammered to form desired form.

Repoussed leaves start off as flat pieces of bronze, then hand hammered to form desired form.

This flower started out life as a flat piece of bronze sheet metal. The piece was formed into it’s beautiful final state by the art of repousse (a method of creating a relief design by hammering the back side of the metal).

This flower started out life as a flat piece of bronze sheet metal. The piece was formed into it’s beautiful final state by the art of repousse (a method of creating a relief design by hammering the back side of the metal).

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Hand Forged Iron Grill

Hand forged & fabricated iron grill with cast steel corner medallions and post repoussed leaves.

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