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CUSTOM HARDWARE; Finest Doorknobs, Escutcheous, Cremone Bolts, Flush Bolts, Sash Locks, Antique Key match to your design or existing





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.

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing


Cast and machine components, make fretwork cut steel ways, mechanism fabrication.

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing


Assemble lockset and confirm functionality as fabrication progresses.

 





Cast spindle fittings, machine strike bolt

 





Fabricate new leaf springs for mechanism

 





  • •  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.






  • •  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,





four custom cast bronze escutcheon plates, swiveling keyhole escutcheon, surrounded with custom fabricated rope trim

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing


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.

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing


Models negatively molded in blue silicone before casting wax positives

 





Handles set up on tree, with sprues to carry bronze into mold

 





Trees coated with ceramic frit, to be baked at 1200 deg. F. kiln into hard ceramic to remove wax and harden for bronze pouring

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing



Ceramic mold firing at 1200 deg. F

Bronze melted inside crucible at 2400 deg.F



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing



Bronze poured into ceramic molds

Ceramic hammered off molded parts







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.

 





  • •  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.







  • •  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.







  • •  Turned Nuts for Bolts, with Notched Exteriors



  • •  Hooks, Sawn, Brazed, Drilled and Pinned to Rods







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.

 



Latch to Secure swiveling Handles with Knob, Lost Wax Cast, Sanded, Polished, and chemically patinated and paste waxed to match original hardware.

 





Train Gate Saddles replaced to handle heavy traffic loads of modern baggage handlers



custom hardware restoration Train Gate Saddles in Poor Condition

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.



custom hardware restoration After fabrication


A-36 Steel utilized for Saddle Replacements


Blacksmith uses a hardened steel file to hand forge a wood gouge for carving.

Olek Lejbzon & Co. shop made propane furnace is used to heat the steel, and hammer on an anvil to create the curved profile requested by our wood sculptor. Various templates are used with the anvil, called hardies, to assist the shaping of the metal. Following the forging of the steel, annealing and tempering is required in a Heat Treatment Furnace to prevent brittleness and to develop the proper hardness for the steel.

Click to see video





Bronze Molded Solarium and Entry Door Restoration, ca.1875



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

 



Screws for Bronze Frame


mis-sized locksets cut into door, to be replaced and restored with appropriate lockset, and refinished


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.

 



Molding hinge made


Matching moldings milled




Replicas fabricated of bronze and steel. Original to left of replica.


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.

 



Holes welded closed, special wide backset locks machined to fit into close to original locations on door lockset housing


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.

 





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.

 





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.



Antique Nickel Plumbing Fixtures Before Restoration Antique Nickel Plumbing Fixtures After Restoration

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.


Vanderbilt House Hardware Restoration Replica Hardware for Vanderbilt

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.


Hardware Restoration Victorian Hardware Restoration

Original nickel plumbing hardware before restoration.
After polishing.

Hardware Restoration Victorian Hardware Restoration


Custom Hardware Gallery



     Japanese Ambassador′s Residence                                                                Fort Hamilton




            Custom Spring Fabrication