50 replies to this topic

[David Browne]

Danger Dillon, on 14 March 2010 - 01:54 PM, said:

Very cool, looks like a different gate from the back. My recent gate had the same effect with the use of the plate. Would have like to see you forge the skeleton part though, budget constant or other factors that led you to use the angle?

As much as I like to forge, I actually never saw this project as a forging job. Although the front and back are different, they still need to relate to each other. I specifically wanted to use heavy angle because: 1) It gave me a nice 2" wide flat surface to hang the panels from (and hide some welds behind). 2) Even with one leg cut short, it still has plenty of strength in three dimensions 3) With the leg cut off, it looks unique and skeletal, but still has the industrial feel of a traditional structural, which to me seemed consistent with the overall vision.

Also, this was always intended to be a naturally rusted piece hence the cor-ten. It would seem a shame to put effort into forging, only to have it covered over with heavy rust...

[Fe-Wood]

David-
Outstanding design and work! I hope you share pictures of it installed to gain context with the site.

I have to disagree about rusted forgings- Ever been to the ghost town of Bodie, Ca.? Some of the best rusted Iron I've ever seen!

[Danger Dillon]

Thanks David,

A traditional industrial structure, I like it, nice juxtaposition. Its a beautiful gate.

[David Browne]

Fe-Wood, on 15 March 2010 - 02:15 AM, said:

David-
Outstanding design and work! I hope you share pictures of it installed to gain context with the site.

I have to disagree about rusted forgings- Ever been to the ghost town of Bodie, Ca.? Some of the best rusted Iron I've ever seen!

Thanks Fe-wood. Point taken- I have been to Bodie...

[David Browne]

Danger Dillon, on 15 March 2010 - 07:16 AM, said:

Thanks David,

A traditional industrial structure, I like it, nice juxtaposition. Its a beautiful gate.

"Traditional industrial" I like it.

Now I've got some additional work to do on the smaller gate. Sorry, no photos yet...It is mounted on a free-standing post that I am unable to tie into the wall. The small gate is pretty heavy as well. When we mounted it in the shop the post deflected 3/8" from the weight of the gate. The post was 2 x 2 x 1/4 (I tried to get away with what I had in the rack). I'm going to go with 3 x 3 x3/8" and I'm thinking about either using a gusset made out of the leg-less angle as a stiffener...or welding the post to the floor mounting plate with some built in deflection to compensate....
-DB

[RoryMay]

Quote

I'm working out a very simple latch system that uses an offset round counterweight that pushes a sliding bolt that will go "klunk" when it's opened, and "klunk" when it's locked (think eccentric on a mechanical power hammer). I'll get you a picture when I get it worked out

Nice! Some doors we have done have that noise. Its odd how comforting that noise is with motion to open or close. I don't know, maybe Im weird. Satisfies that voice in my head when I experience it. Other than a jail cell I dont know where I wouldnt want to hear that lol.

I like how clean both sides are, especially the back.

[David Browne]

The small gate is now complete. The larger thicker-walled side post took care of the sag/deflection issues we were having. I've also included some photos of the "klunk-lock" mechanism in open and closed position. For the handles and the counter-weights, I used discarded cutout plugs from my waterjet cutter. Whenever he cleans out the bed of his large machines there is always a huge pile of wet sand and slugs that he lets me sort through for usable discs ranging from 1/4" thick up to several inches thick in various diameters and alloys. A five gallon bucket lasts me forever and the rest he recycles. The handle plugs were 1 1/2 x 3 forged down on the power hammer to soften and bulge the sides. I finished getting the rust patina on the gates this weekend and will install the pair early this week (in plenty of time before my client's party next weekend). I'll try and get photos after installation (with permission), so you can see them in context.
-DB

[Danger Dillon]

Lookin good, 5 days ahead of schedule.... You the man!

I like the signature block, nice touch.

[youngdylan]

David Browne, on 21 March 2010 - 12:59 PM, said:

I used discarded cutout plugs from my waterjet cutter. Whenever he cleans out the bed .....-DB

I'm liking what I see ... a lot!

Had me going there for a minute, thought your workshop was pretty well equiped if you had a waterjet cutter in it

[beth]

what beautiful gates david - and totally unique. i really love them! thanks for all the posting - amazing work

[Colleen]

Great work, as Beth said, absolutely unique. Love the colour of that corten. Can't wait to see photos in situ.

[David Browne]

RoryMay, on 21 March 2010 - 10:03 AM, said:

Nice! Some doors we have done have that noise. Its odd how comforting that noise is with motion to open or close. I don't know, maybe Im weird. Satisfies that voice in my head when I experience it. Other than a jail cell I dont know where I wouldnt want to hear that lol.

I like how clean both sides are, especially the back.

Rory, I love that sound too! I don't think you are weird at all, but you are sounding a little suspiciously like an "artist"...

[Fe-Wood]

Ya-I was thinking Wow! he has a water jet? Phew, its a friends. I'd be really envious if you had one...

I hope I don't come off sounding mean or critical- I REALY like the design and execution but one thing- Those pop rivets gota go... Unless they are tamper proofs and I can't see the full detail. Otherwise beautifully done! I hope the owners give you permission to share!

[David Browne]

Fe-Wood, on 21 March 2010 - 10:35 PM, said:

Ya-I was thinking Wow! he has a water jet? Phew, its a friends. I'd be really envious if you had one...

I hope I don't come off sounding mean or critical- I REALY like the design and execution but one thing- Those pop rivets gota go... Unless they are tamper proofs and I can't see the full detail. Otherwise beautifully done! I hope the owners give you permission to share!

Fe, I assure you there are no pop rivets on this gate! I had to go back and look at my photos to see what you were referring to. I see now. The ones that you are thinking are pops rivets are actually stainless button head allen drive fasteners (drilled and tapped). I had to use these because I didn't have enough clearance to get a solid rivet in there. I'm going to blacken them and they should disappear. Thanks for the kind words and for not letting me get away with any shortcuts.
-DB

[Fe-Wood]

Sorry-
Shoulda know better
I did a double take and tried to get a close up...

[David Browne]

Installation went pretty well. Everything fit, and no fingers or toes got crushed. I call that a good day. Luckily there was a contractor and a stone mason on site doing some additional stonework on an outdoor barbecue. They helped us carry the large gate up the stairs and set it into place on the hinge pin. Apologies- the photos are not very good. It was too shaded near the large gate and too much sun washed out the small one. But, hopefully you get the idea of the context. The small gate leads to a deck overlooking downtown San Diego, the bay and the ocean.
-DB

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[youngdylan]

Even better seeing them in situ. Great stuff David

I love the colours on the Corten, does do they stay that vivid or do they develop into more of a dark chocolate colour

[David Browne]

youngdylan, on 25 March 2010 - 04:39 AM, said:

Even better seeing them in situ. Great stuff David

I love the colours on the Corten, does do they stay that vivid or do they develop into more of a dark chocolate colour

Youngdylan,
The cor-ten (A588) is pretty interesting stuff. I really like the variation of colors that it has at present as well, but it will continue to darken to a more uniform medium/dark brown over time. How much time depends on the environment. Probably 1 or 2 years. The thing that is really interesting about this steel is the tightness of the rust pattern. By all appearances, the gates look like they are covered with a rust that will rub off on you if you brush against it (that's what we are used to). BUT...you can run your hand across them and nothing comes off. It is a really tightly contained color that has seemingly sealed itself. Pretty cool, huh?

[Danger Dillon]

Those look awesome! Rust is my favorite color, nice job, enjoy the party you deserve it.

[youngdylan]

David Browne, on 25 March 2010 - 08:48 AM, said:

Youngdylan,
The cor-ten (A588) is pretty interesting stuff. I really like the variation of colors that it has at present as well, but it will continue to darken to a more uniform medium/dark brown over time. How much time depends on the environment. Probably 1 or 2 years. The thing that is really interesting about this steel is the tightness of the rust pattern. By all appearances, the gates look like they are covered with a rust that will rub off on you if you brush against it (that's what we are used to). BUT...you can run your hand across them and nothing comes off. It is a really tightly contained color that has seemingly sealed itself. Pretty cool, huh?

Now that is pretty cool. From the pictures is does look like it will wipe off. I really wanna have a go a using cor-ten now, guess this will make is easier to "sell" the idea of a "rusty gate" to customers. Kinda the "anti stainless steel"

Is it available in a good choice of sections or is it mainly plate. How does it compare cost wise to "normal" steel

Over here we've got quite a famous piece of sculpture made from cor-ten that gets a lot of publicity; "The Angel of the North"