Hello all,
I was recently commissioned by the Ravens to create door pulls for the pro stores around the concourse level of the stadium. A few people have shown an interest in how I fabricate wings so I took some process photos this time around.
#1- concept drawing
#2-cardboard template from drawing transferred to 1/8" stainless steel plate
#3- front and back blanks with feather indications
#4-blanks bent to shape cold, sections that have too tight a bend are forged hot over a crude ball shape tool I clamp in my vise
#5-blanks welded around perimeter like a pillow
#6-piece added to close off bottom
#7-rough grinding to bring out feather shapes
#8-welds added to make feathers pop a bit more
#9- welds ground smooth, ready for detail carving with a straight die grinder and pencil grinder with various shaped carbide burrs
#10- finished front. details carved in, a little black shoe polish rubbed on to bring out details
#11-finished back of wing
At this point they were really digging what I had made and doubled the order to 28 wings total. At 12hrs each to fabricate and some other work all due in a month, I decided to cast them in bronze at a foundry I used to work at.
#12-first batch of bronzes
#13-I had the bronzes nickel plated since they wanted a steel look
#14-I applied Sculpt Nouveau Magic Black to get the antiqued effect
#15- Finished!