MCKAY FORGED METALS
The Process
From the conception to the installation. How I create a piece of ironwork.
Drawings are Essential
Whether it's a simpler project or a complex one, drawings are essential to work out the details to create thoughtful designs.
Rendered in micron pen and charcoal.
Many projects begin by using a hammer and an anvil to forge components. This is the foundation of what I do and I stick to it as much as I can.
For larger material, the force required to move the metal efficiently can only be achieved by using the power hammer. This tool can also speed up the production of components when used properly.
Forging
When forging there are many traditional techniques used or expanded upon. For millennia, the way steel has been manipulated has used the same core principles: heat, force, and surface area contact. Virtually anything can be created with the proper control of these principles.
The forging process produces elegant details that tell the story of how each individual piece was made.
The assembly process requires the use of a wider variety of tools, though forging is still often the primary technique used in assembly. Rivets or riveted tenons are forged to secure parts. If elements need to be removed bolts or mechanical wedges are used instead.
Assembly
Now, what about welding? Some people love it, some people hate it, but sometimes it's just necessary. This photo for example shows welded connections, but they are used in a way that maintains the piece's beauty and structural integrity.
Finishing & Installation
The finish put on ironwork is one of the most important parts of the process. It ensures that the work maintains the appearance it had the day it was completed. There are many finishes that can be used, varying based on where the piece will live.
Installation varies from site to site, but all use some form of fastening to an existing structure. If the piece needs to be removed, that would require a different solution than those that are permanent. Installation may also involve altering the structure to create a solid backing for the hefty piece of metal.
... and now we have a new piece of ironwork, hot off the forge!