A couple of photos from the workshop at the end of last week. The blinding bright light shows me TIG welding an arrow to the bar for a weathervane sail, while the top image shows a bespoke deer weathervane clamped to the workbench ready to weld. It needs to be clamped securely to avoid the heat from the weld warping the design, as this could actually prevent the weathervane from functioning. The bespoke deer design features a fawn as well as the doe and stag, stood in fern based undergrowth. This one has now been electroplated and powder coated, so will be ready for packaging and dispatch this afternoon.
We finished welding this bespoke swinging sign yesterday. The design shows two Pygmy goats and a Labrador, the customer’s pets. I’ve tried to show the goats in quite a playful light, reflecting their curious and mischievious personalities, so one has climbed onto a tree stump and the other looks up to him in an inquisitive manner. The Labrador is watching over them, as usual fascinated by what his two companions are up to. It’s great to be able to personalise a hanging sign design to this extent; as well as getting the look of the animals right, from speaking to our customers we can also get an insight into how their animals interact with each other, and allow that to inform the design.
As the sign will be mounted to the top of a chunky gatepost rather than a wall or the side of a post, we’ve produced a different bracket to our standard. We’ve used 50x50mm box section for the vertical, and 30x30mm for the horizonatal bar, so is very sturdy and built to last. The hand forged scroll on top adds to the traditional look of this bespoke hanging farm sign.
This set of hand forged coat hooks features a bespoke laser cut design, created at the end of last year. The dog is based on a photo of the customer’s own working border collie, so it’s a really unique and personalised piece. Because her legs are mostly white, I was initially concerned about the design being too delicate, but with a generous black outline, the profile cut in 3 mm steel and a could of blades of grass supporting at the back, this was not an issue. We love the stance of the Border Collie as she herds the sheep; I think the design feels very life like and fluid. The hooks are forged by hand from 6mm steel bar, with decorative ‘rat’s tail’ ends to prevent clothes snagging.
A stunning laser cut Apple Tree sign we designed and produced recently. The customer specified that she’d like quite a detailed, ornate design, but as the sign would be mounted to a fence, it also needed to be strong enough to withstand accidental damage. The sign is cut in 3 mm steel, and during the design process I took care to make sure that any delicate parts such as unsupported leaves are joined to branches or apples for extra strength, but without affecting the look of the design. Due to the complexity of the design, this took much longer to cut than most of our designs and therefore cost more than the standard signs shown on our website. We love how the house sign has turned out, I think the art nouveau inspired design is truly unique and stands out as a piece of art as well as a functioning house name plate.
A Drummer weathervane we designed and manufactured at the end of last year – it’s good to see our range of music themed weathervanes growing. Initially I couldn’t decide whether the image would work better as a side profile or front on, so ended up drawing both and giving the customer the choice; this is what she went for. We felt this design would work better mounted centrally and with a tail at the end, as with the bass drum especially being cut out, there isn’t actually that much surface area to catch the wind, so it functions better this way. A great personalised gift for anyone who plays the drums!
A bespoke weathervane design we produced at the end of 2017 – we’ve just rediscovered it now while looking through customer photos sent in during 2018 in order to choose the winner of last years’ photo competition. We love how the deep blue sky makes the weathervane stand out! It’s also taken from a great angle, as all the letters are the right way round and the sail has spun so we have a very clear view of the design.
In terms of creating this weathervane design, the main difficulty was the Kingfisher. The customer comissioned this bespoke weathervane for her husband, who is a wildlife photographer. She wanted the bird to be in the image as well as the man taking the photograph, which was tricky because of the difference in size; if the bird was actually to scale it would have been so tiny you wouldn’t have seen it when mounted on the roof. By making the Kingfisher design part of the tail & therefore a seperate component to the photographer profile, we felt he seems as though he is in the foreground, rather than just being a disproportionately large bird, which I think was a risk if we’d made him part of the main laser cut design. A fantastic personalised gift for a wildlife and photography enthusiast!
A Basset Hound weathervane we designed and manufactured at the end of last year. As our designs go, this one was reasonably straightforward as the dog is standing in side profile, though at the research stage we needed to look into specifics of the breed standard to make sure everything was exactly right. After showing the design to the customer we made a few tweaks to get the angle of the tail correct, but other than that we were ready to go with it. This bespoke weathervane was produced for a customer who’s Basset Hound had recently passed away; it’s nice that he is now looking down on the family and makes a lovely tribute to a much missed pet.
Another of the bespoke weathervanes we produced at the end of 2018. The design is based on Edinburgh castle, a landmark local to the customer which dominates the skyline of the city. It was quite a challenging design to create as it’s an absolutely huge castle with loads going on, but the details were difficult to show in silhouette form. The fortress sits at the top of a rocky hill, which I’ve tried to show using small angular cut outs at the base of the design, as if light is reflecting off the surface of some of the rocks. Another thing I found when creating this design was that with the castle being so old, no part of the building is straight; when I began the drawing I used the computer to draw, for example the roof line, which because it was drawn on the computer, was perfectly straight. I was suprised at how odd this made it look! So I ended up following the roof line by hand with my graphics pen, which as I’d done it manually was not perfectly straight, and so far more true to life.
The hikers, shown as if in the foreground walking away from the castle, are a nice detail as it adds a bit of a narrative to the otherwise static design, I think it breaths some life into the scene of this famous 12th century castle. We loved creating this bespoke weathervane as it’s a landmark we know well from trips up north; we hope we have done it justice!
We designed and produced loads of bespoke weathervanes in the run up to Christmas, so thought we’d write a post showing the process involved in welding the sail. Firstly the bar is cut to size for the weathervane sail and cleaned with the angle grinder, removing any mildscale and dirt that could contaminate the weld. The customer had chosen the Celtic arrow, so this is clamped to the bench along with the bar, making sure they are straight and in line with each other.Once TIG welded on all four sides, the arrow and bar can be left to cool, which in our freezing cold workshop does not take long in December! The Irish Terrier profile is cleaned to remove any burrs from the cutting process, as is the top of the bar where the profile will be welded. This is then clamped tightly to the bench to ensure it is straight; if it’s leaning to one side the wind will catch the sail & just spin continuously rather than pointing into the wind as it should. Both sides of this are TIG welded.Once cool, we need to find the balance point on the weathervane sail. Because the arrow is cut from much thicker steel than the Irish Terrier profile, this point is usually somewhere in the centre, though it’s important to be precise or the weathervane won’t function correctly. This point is marked with chalk, and the mildscale cleaned off.A length of tube is now cut to size, and both ends cleaned to remove burrs and any grease or dirt, and finally a light sanding smooths off any grinder marks.The tube needs to be welded on at exactly 90 degrees, so we use a magnet to hold this angle while it is tacked in place. A set square is used to keep checking the angle as metal has an annoying tendency to pull one way or another as it heats and cools! It also needs to be straight in the other direction so it’s in line with the Irish Terrier profile, otherwise it would lean to one side when mounted & therefore not catch the wind properly. The photo below shows the weathervane sail welded completely, and ready to be zinc electroplated & powdercoated with whichever fixing and letter bar option the customer has chosen.
We designed and produced this beautiful bespoke house sign at the end of last year. The design features our customer’s rust coloured Border Collie lying in side profile, and the top of the oval sign is framed with an ornate Rose and Ivy design. Initially we discussed with the customer having her house name around the top of the sign and the number at the bottom, but with it being quite a long name the letters ended up tiny in order to fit, so we decided against it. The ornate Rose design came about because the dog’s name is Rosie. We think this makes the sign such a unique and personalised piece rather than just having the name, and a piece of wall art in it’s own right as well as being a functional house number sign.
The house sign is cut using a nitrogen shrouded laser in 3 mm steel, and the finish is a layer of zinc electroplate followed by a traditional looking but very hard wearing black powder coat. The customer specified an RAL code to paint Rosie the Collie which closely matches the colour of her coat, this was mixed and painted by hand in outdoor paint.