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CUSTOM HARDWARE; Finest Doorknobs, Escutcheous, Cremone Bolts, Flush Bolts, Sash Locks, Antique Key match to your design or existing
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| Original knob at lower left, with various stages needed to complete chasing: top right, from kiln, cleaned. Top left, polished prior to chasing. Below right, after chasing- all details same.
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| Cast and machine components, make fretwork cut steel ways, mechanism fabrication.
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| Assemble lockset and confirm functionality as fabrication progresses.
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| Cast spindle fittings, machine strike bolt
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| Fabricate new leaf springs for mechanism
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• Deadbolt patterned after original,
• With exterior keyhole and
• interior thumbturn, and
• custom strike plate and
• lockset edge plate, machined on vertical milling machine and broached to match original.
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• custom springs that were forged of 1085 spring steel, hardened at 1800 deg.F, and oil quenched, polished to remove microstress cracking, tempered at 900 deg. F and oil quenched, annealed at 300 deg. for 2 hrs., and
• strikes machined and broached, with
• skeleton keyed activation,
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| four custom cast bronze escutcheon plates, swiveling keyhole escutcheon, surrounded with custom fabricated rope trim
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| Four door knobs lost wax cast of matching bronze, chased to impress the whisker and fur and rope texture details, with lathe turned handle shafts, sanded and polished, then chemically patinated to match the originals. Drilled and tapped to match spindle threading, spindles pinned to shaft.
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| Models negatively molded in blue silicone before casting wax positives
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| Handles set up on tree, with sprues to carry bronze into mold
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| Trees coated with ceramic frit, to be baked at 1200 deg. F. kiln into hard ceramic to remove wax and harden for bronze pouring
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Ceramic mold firing at 1200 deg. F
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Bronze melted inside crucible at 2400 deg.F |
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Bronze poured into ceramic molds
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Ceramic hammered off molded parts |
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| Solid Brass Custom Casement Sash Locks, each consisting of 14 separate machined and cast brass components, highly polished and chemically patinated to match the originals, overall approx. 32" long, each weighing 5 lbs. 6 oz. with total of 200 separately manufactured custom pieces, total net weight 54 lbs.
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• Brass Rod ?" diam. x 32" long.
• Cast Brass Handle Attachment with Split "Ears", drilled to fit the rods, and attach the handles, 4" x 1" x 1 ?", machined for handle attachments and fit..
• Swiveling Handles with Machined and Sawn ?" Flat Stock pinned to Handle Attachments, with curved and rounded design, forms cam locking mechanism.
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• Turned Ball End of Handles, 1" diam.
• Bolts with Turned Spherical Heads 1" diam., with Machined and Threaded Bolt Shaft, the Spherical Heads Drilled to fit around Rods.
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• Turned Nuts for Bolts, with Notched Exteriors
• Hooks, Sawn, Brazed, Drilled and Pinned to Rods
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| Pins, two pressure fit pins in hooks to rods, one riveted from Handle to Rod Attachment, two machined and tapped through Rod Attachment to rod with heads ground smooth.
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| Latch to Secure swiveling Handles with Knob, Lost Wax Cast, Sanded, Polished, and chemically patinated and paste waxed to match original hardware.
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Train Gate Saddles replaced to handle heavy traffic loads of modern baggage handlers
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Train Gate Saddles in Poor Condition, originals were made of thin cast iron, too brittle for 2 ton carts rolling over them. We re-designed the Saddle, machining 1" thick A36 steel, but keeping the original appearance and working with historic gates.
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A-36 Steel utilized for Saddle Replacements |
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Bronze Molded Solarium and Entry Door Restoration, ca.1875
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| Bronze Framed Solarium missing moldings, and also requires recaulking of all glass. Requires new moldings milled and approx. 800 custom Jackson head screws cut down on a lathe to replace weak originals that break on removal, and mismatched prior replacements
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| Solid bronze entry door had molding elements cut away to install closer, and mis-sized locksets cut into door, to be replaced and restored with appropriate lockset, and refinished.
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Matching moldings milled |
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| Original oversized thumbturn knobs broken and missing, overstressed by activating Cremone Bolts for 7' doors since their 1875 fabrication. Replicas fabricated of bronze and steel. Original to left of replica.
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| Original lockset housing had extra holes cut for mis-sized replacement locksets. Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing.
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| Solid bronze 18' high radius window frames restored for this ca. 1875 Solarium. All bonze moldings and all radius glass removed, restored, new glazing putty installed for weatherproofing, and 800 new custom-machined "Jackson" head screws lathe-turned in our machine shop to replace original crystallized screws for replacment of moldings.
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Exotic Historic Plumbing Hardware restored
Restoration and replication of solid nickel and brass hardware for Japanese Ambassador's Residence, at 11 East 62nd St, New York City. Formerly the residendce was built for Margaret Vanderbilt Shepard's (daughter of William Henry Vanderbilt) and her husband's, Ernesto Ferri, residence, ca.1895. The existing 120 year old hardware was salvaged, restored, and reused in the residence, including custom solid nickel plumbing fixtures, locksets, ornate bronze, steel, and iron hinges. Plumbing fixtures were taken apart, all faucet valve seals re-ground or replaced. Valves were repacked and caulked, for new performance and functionality. Even the janitor's sinks in this 50' wide 7-story 35,000 sf townhouse were made of solid nickel.
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Before condition looked like brown, rusted steel. |
Solid nickel Tub Filler, ca. 1895 - all machined surfaces reground, washers & bushings replaced, ready for next century of service. |
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Double-swinging bronze door hinges welded to repair cracked leaves. |
Ornate bronze and steel pin hinges 10" high supporting massive bifold doors replicated, using horizontal milling machines, & lost wax casting. |
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Original nickel plumbing hardware before restoration. |
After polishing. |
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Custom Hardware Gallery
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Japanese Ambassador′s Residence Fort Hamilton
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Custom Spring Fabrication
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