Category Archives: Historical Reproductions

Reproduction of the Original Vanderbilt Mansion (Hyde Park) Light Fixtures

Click photo to see job details

ORIGINAL

Vanderbilt Mansion was built in 1899. Pictured here is one of its original wall sconces. Keicher Metal Arts restored the four existing originals AND fabricated two new sconces to match the originals.

RESTORATION
of an ORIGINAL
Keicher Metal Arts meticulously restored the four original sconces back to their former glory. We disassembled the original fixtures and developed a full set of very detailed shop drawings. We restored what was salvageable. For those components that couldn’t be reused we fabricated, forged, machined, and spun replacement pieces. After reassembly, all surfaces were then primed and painted with high performance coatings. Lastly, new wiring, sockets, LED bulbs, and glass were installed.

REPRODUCTION

Keicher Metal Arts reproduced two new wall sconces based on the shop drawings that we made from the original sconces. All new components were reproduced using historically correct methods and materials. This included hand forging, cold forging, repousse, machining various fittings, and fabricating & welding the lantern bodies.

Hard to tell the difference between the restoration and the reproduction, isn’t it?

 

NEW PENDANT
Keicher Metal Arts fabricated two new wrought iron pendants. Unfortunately there were no originals left so the design of the new pendants was based off of the wall sconces.

Close-up of a new pendant.

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.
The scroll at the top of this picture is the first part of a scroll jig that was used to straighten damaged scrolls and form new ones.

 

 

Closeup of 4 piece joint

 

 

 

 

 

 

Restored Railing

Restored Entrance

 

 

 

 

 

 

 

 

Historic Bronze Torchieres

Click photo to see job details

The original torchieres, which were natural gas powered, were melted down for the war effort. Since none existed to take patterns from, we reproduced them from historic photos and extremely detailed architects’ drawings from John G Waite and Associates.

The original torchieres, which were natural gas powered, were melted down for the war effort. Since none existed to take patterns from, we reproduced them from historic photos and extremely detailed architects’ drawings from John G Waite and Associates.

Each torchiere is 14’ tall and is comprised of 70 components. Several processes were used in fabrication such as casting, metal spinning, lathe turning, machining, water jetting, welding, brazing, polishing, etc. We hand-carved approximately 20 different patterns and molds for both lost wax and sand cast components. The globes were custom made. All fixtures are UL approved.

Each torchiere is 14’ tall and is comprised of 70 components. Several processes were used in fabrication such as casting, metal spinning, lathe turning, machining, water jetting, welding, brazing, polishing, etc. We hand-carved approximately 20 different patterns and molds for both lost wax and sand cast components. The globes were custom made. All fixtures are UL approved.

IMAGE_1_22092009094607.jpg

Dsc02343a

fader

Dsc_0049a

IMAGE_1_21092009132936.jpg

Dsc_0051a

Hand carved hub pattern (at mid point in the torchiere)

Hand carved hub pattern (at mid point in the torchiere)

Hand carved leaf cross arm pattern

Hand carved leaf cross arm pattern

Hand carved pattern for octagon base shaft

Hand carved pattern for octagon base shaft

Closeup of hand carved base shaft pattern

Closeup of hand carved base shaft pattern

Closeup of octagon base shaft

Closeup of octagon base shaft

Historic Bronze Elevator Entrance Reproduction

 Click photo to see job details 

Vintage photo of the original elevator entrance

Vintage photo of the original elevator entrance

IMG_3525a

These elevator entrances are replications of the original historic entrances. Job included cast and fabricated bronze hoistway doors & entrances, hand forged bronze grills, and bronze elevator cabs. Processes used were lost wax & sand casting, repousse, hand forging, and various other fabrication techniques.

IMG_3575a

IMG_3587a

IMG_3590a

IMAGE_1_22092009065655.jpg

IMG_3593a

Elevator cab interior consists of custom bronze wall panels with fabricated grecian grills.

Elevator cab interior consists of custom bronze wall panels with fabricated grecian grills.

Elevator cab ceiling in bronze with a custom curved crown moulding.

Elevator cab ceiling in bronze with a custom curved crown moulding.

IMG_3529a

IMAGE_1_24092009110848.jpg

Dsc00097a

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).

Dsc00137a

Custom Historic Bronze Hinge

This is a replication of the historic custom hinges that were original to NYS Capitol. The patterns for both the finials and back plates are hand carved. The components are replicated by using the lost wax casting process. The actual hinge leaves are sand cast and all components are machined and hand chased.

Installed hinge

Installed hinge

Just an fyi...We made the 14' tall bronze torchiere in the background too :)

Just an fyi…We made the 14′ tall bronze torchiere in the background too 🙂

Ornamental Aluminum Metalwork for the Historic Assembly Staircase Laylight in the NYS Capitol

Click photo to see job details

During WWII, the skylights in the NYS Capitol were painted black for safety reasons. These areas were eventually converted to office space. During a major roof renovation in the 2010 timeframe this skylight & laylight were revealed and brought back to their grandeur and flooding the stairway with natural light.

During WWII, the skylights in the NYS Capitol were painted black for safety reasons. These areas were eventually converted to office space. During a major roof renovation in the 2010 timeframe this skylight & laylight were revealed and brought back to their grandeur and flooding the stairway with natural light.

We made the custom aluminum framework for the decorative glass for the laylight over the NYS Assembly Staircase.

We made the custom aluminum framework for the decorative glass for the laylight over the NYS Assembly Staircase.

11506.28.002b