kustomsteel Posted August 26, 2013 Share Posted August 26, 2013 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! Quote Link to comment Share on other sites More sharing options...
petere76 Posted August 26, 2013 Share Posted August 26, 2013 Kustom, Excellent work sir. Thank you for sharing your technique and photos . I am confident your client is very happy. Peter Quote Link to comment Share on other sites More sharing options...
DSW Posted August 26, 2013 Share Posted August 26, 2013 Beautiful work. Out of curiosity what is the ball park cost to have something like that cast commercially? I've always wondered what having something like that done would cost with setup and so on. Quote Link to comment Share on other sites More sharing options...
bigfootnampa Posted August 27, 2013 Share Posted August 27, 2013 Interesting work! I would like to see a picture of one installed! They look great! Quote Link to comment Share on other sites More sharing options...
windancer Posted August 27, 2013 Share Posted August 27, 2013 Exceptional work all around! Your communication skills obviously worked very well, too. I am always amazed when all the talk ends up being what everyone had in their own minds. 1st rate work! Dave Quote Link to comment Share on other sites More sharing options...
MLMartin Posted August 27, 2013 Share Posted August 27, 2013 They look great! Did you really cut all those tiny feather lines with a die grinder? How small a burr bit did you have?, or cut wheel? Quote Link to comment Share on other sites More sharing options...
Dillon Sculpture Posted August 27, 2013 Share Posted August 27, 2013 Killer Kustom, keep them coming! I like the texture and smooth surfaces together, organic and armor-ish. Quote Link to comment Share on other sites More sharing options...
kustomsteel Posted August 27, 2013 Author Share Posted August 27, 2013 Thanks for the comments. DSW the molds were $250 each (1 left 1 right) and each casting is $325. I did all the metal finishing and patina so that brings the price down. Bigfootnampa they were sent the wrong doors so when they straighten that out I'll get installed pics. Yes Peter and Dave, this job went fairly smooth considering the time crunch, client is talking about a lot more work spinning off of this project. MLMartin I'll try to post some pics of the burrs I use- it actually goes quicker than you think. But man is that stainless tough, I don't think my hands would survive 28 of them! Quote Link to comment Share on other sites More sharing options...
kustomsteel Posted August 27, 2013 Author Share Posted August 27, 2013 Killer Kustom, keep them coming! I like the texture and smooth surfaces together, organic and armor-ish. Thanks danger, I was hoping you would see this. I forgot to mention that these are being mounted on glass doors so you will see that contradiction in surface. Quote Link to comment Share on other sites More sharing options...
HIGHSIDER Posted August 27, 2013 Share Posted August 27, 2013 Wow there something else..love the finish. Great work, very well done Quote Link to comment Share on other sites More sharing options...
Steve Sells Posted August 27, 2013 Share Posted August 27, 2013 First class, I am sure the client thinks he under paid you. Quote Link to comment Share on other sites More sharing options...
Frosty Posted August 27, 2013 Share Posted August 27, 2013 Outstanding work. Isn't it grand how one bit of excellent work leads to a demand for more? Frosty The Lucky. Quote Link to comment Share on other sites More sharing options...
Paul Crosby Posted August 28, 2013 Share Posted August 28, 2013 Wow! Very beautiful!! You have to be very proud of those! Quote Link to comment Share on other sites More sharing options...
Old South Creations Posted August 28, 2013 Share Posted August 28, 2013 beautiful work! Quote Link to comment Share on other sites More sharing options...
K. Bryan Morgan Posted August 29, 2013 Share Posted August 29, 2013 I can't use the words I want to because they will just end up looking like this. XXXX XXXXXXX XXXX XXXX XXXX Quote Link to comment Share on other sites More sharing options...
kustomsteel Posted August 30, 2013 Author Share Posted August 30, 2013 Thank you all for the comments, and yes Frosty but that demand is slow coming for me. Maybe that's a good thing! Quote Link to comment Share on other sites More sharing options...
Camero68 Posted September 11, 2013 Share Posted September 11, 2013 Excellent work! Those wings look like real feathers and the finish is so smooth and flawless. Thanks for sharing the great photos as well. Quote Link to comment Share on other sites More sharing options...
tzonoqua Posted September 11, 2013 Share Posted September 11, 2013 wonderful work!! great attention to detail, surface finish and they look so tactile!! yum!!! Quote Link to comment Share on other sites More sharing options...
sfDuck Posted September 16, 2013 Share Posted September 16, 2013 Jeeez I just get back to the site after 2 yrs of no puter an I see your wings...........! Things just keep getting better an better round here.........Duck Quote Link to comment Share on other sites More sharing options...
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