tag:blogger.com,1999:blog-1547718577194503432024-03-26T02:03:17.392-07:00Orion ForgeBend Oregon's source for custom iron work, blacksmithing, wrought iron furniture, architectural iron work
and metal sculpture art.Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.comBlogger95125tag:blogger.com,1999:blog-154771857719450343.post-50298969380105800892016-05-05T10:39:00.001-07:002016-05-05T10:39:57.616-07:00hammer switchin'<div dir="ltr" style="text-align: left;" trbidi="on">
Finally traded off the old Beaudry 150# hammer. Swapped a fella straight across for a Striker 88 pneumatic hammer. And then bought a 300# Chambersburg. I miss the ol mechanical hammer, but not much....<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-35693040210876568652014-10-30T11:51:00.001-07:002014-10-30T11:51:56.379-07:00The Finished Chair.<div dir="ltr" style="text-align: left;" trbidi="on">
After welding a few cross bars, and then cutting them free...<br />
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...we determined the need for a nifty fixture to hold the side rails in place:<br />
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Once everything was locked down, we started welding in the remaining cross bars. Because the different radii of the cross members translate directly to the eventual comfort of the chair, each piece required a notable level of fiddling to position properly.<br />
After welding all cross members, we built the final tools; two small bending jigs for the 1/8 bars (wire) that form the seat and back of the chair.<br />
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After making 38 pieces, we started welding them in place:</div>
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And next thing ya know, we were sitting down on the job.<br />
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Through some rigorous R and D testing, (we each sat in a chair and consumed one ice cold beer, switching seats half way through) we determined the comfort level of the two chairs to be equal. The visual appearance is also dang near identical. <br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-38254459062231862942014-10-28T07:40:00.000-07:002014-10-28T07:43:40.255-07:00Chair building continues....<div dir="ltr" style="text-align: left;" trbidi="on">
Our successful results with the first series of bends bolstered our confidence to continue building jigs and bending tubes. We built a few more tools and before long we had the second part of the main element formed. <br />
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A bit of welding and we had our first completed element.<br />
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With the tools for the main element completed, we began building the tools for the tubes that connect the two sides together. <br />
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We discovered that while similar, the tubes all had unique curvatures, necessitating a handful of new jigs. We also learned that the smaller diameter tubing and the more subtle radii enabled us to make the bends without packing them with sand. After tack welding a few of the cross bars in place, we had a chair shaped object on the table!<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-10415884612051291712014-10-22T18:31:00.002-07:002014-10-28T07:43:54.689-07:00the chair project - an exploration of tube bending, blacksmith style.<div dir="ltr" style="text-align: left;" trbidi="on">
Recently we were contacted by Victoria, creator of <a href="http://www.the595project.com/">the595 Project</a> and were presented with a unique opportunity - re-create a curvy, French, mid-century modern steel chair for clients in California. We met with them, and luckily they were able to provide a chair to use as a template: <br />
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Two things immediately jumped out - first, how cool looking the line that defines the legs, seat and back of the chair is, and second, that that line is constructed with thin wall tubing. We have considerable experience bending solid bars, not hollow ones, and images of misshapen, kinked tubes were easy to conjure. As were the actual, misshapen, kinked tubes once we started figuring out the process:<br />
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We knew that one of the strategies for bending pipes and tubes when one doesn't have fancy hydraulic bending machines is to pack them with sand - essentially just try to make a solid bar out of the thing. Kellen acquired some medium fine sand used for sand blasting, we crimped the ends of some tubes, filled them with sand and started bending. After using about 30 feet of material, what we referred to as the 'learning curves', we figured out the properties and limititations of the material and started bending pieces around some homemade jigs:<br />
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The main curvy lines on the original chairs were made by bending two
tubes and then welding them together so that's what we're going to do. Pictured above is a completed half.<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com2tag:blogger.com,1999:blog-154771857719450343.post-19786494340359771442014-05-21T08:19:00.000-07:002014-05-21T08:19:38.408-07:00hand forged, custom firescreen<div dir="ltr" style="text-align: left;" trbidi="on">
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Found, forged and fabricated firescreen. The vertical panels are made of old steel roofing. I backed them with stainless steel to reflect heat in the hopes that the paint wouldn't get too hot.</div>
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Nearing completion of the latest handrail. The homeowners are building a house with a Moroccan aesthetic and this rail will compliment it nicely. We were forging and setting collars today, and welding (lots of welding on this job) the laser cut panels in place.<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-24524683654305070882014-03-09T18:00:00.002-07:002014-03-09T18:00:35.934-07:00Dragonfly sculpture<div dir="ltr" style="text-align: left;" trbidi="on">
Stopped by a friends house today and got a picture of the dragonfly.<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com1tag:blogger.com,1999:blog-154771857719450343.post-34202774717649948292014-03-09T17:55:00.000-07:002014-03-09T17:55:06.510-07:00Finally! A new website!<div dir="ltr" style="text-align: left;" trbidi="on">
After many years of foot dragging, the new website is up. Check it out at the same place <a href="http://orionforge.com/">orionforge.com</a>. </div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-16615609720311984282013-12-05T08:43:00.003-08:002013-12-05T08:43:54.588-08:00Orion Forge Brand<div dir="ltr" style="text-align: left;" trbidi="on">
yep, Orion Forge, fully branded... made this recently for a christmas tree guy that wanted to commemorate the year on the butt of the trees. <br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-87077401291296844502013-12-05T08:31:00.000-08:002013-12-05T08:34:14.011-08:00hand forged firewood rack<div dir="ltr" style="text-align: left;" trbidi="on">
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A small firewood rack I recently completed. The sheet metal floors are scraps that I used to practice patinas on, they were behind the powerhammer and covered in grease - cleaned up they look great!<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com1tag:blogger.com,1999:blog-154771857719450343.post-9662482959182550392013-12-05T08:28:00.001-08:002013-12-05T08:36:08.619-08:00hand-forged firewood rack<div dir="ltr" style="text-align: left;" trbidi="on">
I just acquired a small combo shear, brake and roll so the small bit of sheet metal work was the perfect project to start dialing in the new (to me) tool. <br />
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Joining the piece was a trick - I finally had to tack weld it so I could set the split tenons. I added the little paper rack after the main rack was joined - bit of a wrestling match setting those rivets!<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com1tag:blogger.com,1999:blog-154771857719450343.post-61647886005982961042013-10-28T11:50:00.001-07:002013-10-28T11:54:16.990-07:00the cantilever table<div dir="ltr" style="text-align: left;" trbidi="on">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMe1BV4a9We1KDo8M-Fc1lsT4uu5w3cS-TsoicHU_RrEwI0AMCR82p-THhjPeAjAbAtUgsfiQDo2s8ZXjERrLjXZKFOBANZnaeAj_4H3vpeIgw6hHmKEEJXBnIObX6GdjiLM6hE8KX93E/s1600/20131003_090537.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMe1BV4a9We1KDo8M-Fc1lsT4uu5w3cS-TsoicHU_RrEwI0AMCR82p-THhjPeAjAbAtUgsfiQDo2s8ZXjERrLjXZKFOBANZnaeAj_4H3vpeIgw6hHmKEEJXBnIObX6GdjiLM6hE8KX93E/s320/20131003_090537.jpg" width="240" /></a>This table features a beautiful slab of double live edge redwood, roughly 9 feet long by three feet wide. The client and I thought it'd be cool to design a base with only one support, not only to minimize the potential for leg obstruction, but also to mimic the cantilever of a plum tree behind the table.<br />
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I welded a sizable anchor to the leg and set it in concrete in a void in the patio slab. Used about 6 bags of redimix.<br />
Table here is freshly sandblasted and ready for the rusting solution. I used a solution of ammonium chloride (NH4Cl) and water.<br />
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Here it is with the concrete still green and a temporary support in place. See that cool plum tree?</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-80141440084393123912013-10-28T11:29:00.000-07:002013-10-28T11:29:08.466-07:00a forgotten sculpture...<div dir="ltr" style="text-align: left;" trbidi="on">
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I was walking through a friends yard recently and saw this sculpture that I built years ago. I'd forgotten all about it! </div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-28022803219792692522013-09-25T20:58:00.000-07:002013-09-25T21:09:36.741-07:00Wrought Iron bookshelf <div dir="ltr" style="text-align: left;" trbidi="on">
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Built this heavy duty <a href="mailto:orionforge@gmail.com">wrought iron bookshelf </a>recently.<br />
Uprights are 1/2 x 3 textured flat bar. All the mortises were<br />
drilled and drifted to accept the tenon on the bracket.<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-49522867808790222482013-09-25T20:18:00.003-07:002013-09-25T21:14:41.530-07:00hooks, with copper rosettes. <div dir="ltr" style="text-align: left;" trbidi="on">
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No doubt about it, blacksmiths make hooks.</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-30019800451188576432013-09-24T19:55:00.000-07:002013-09-24T20:00:34.182-07:00firesculpture finally on display again!<div dir="ltr" style="text-align: left;" trbidi="on">
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Got a request from the folks over at <a href="https://www.facebook.com/pakitliquidators">Pakit Liquidators</a> about using the firesculpture for the upcoming <a href="http://frequency.blogs.bendbulletin.com/tag/bend-roots-revival/">Bend Roots Revival Festival</a> so Kellen (co-creator of sculpture and owner of <a href="https://www.facebook.com/CopperIronCubed">Copper Iron Cubed</a>) and I drug it out of storage and put a fresh coat of wax on it.<br />
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Disassembled, it all fits nicely in the back of the truck.</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-68097424206996385562013-05-23T09:02:00.003-07:002013-05-23T09:02:56.672-07:00completed custom barn doors and roller track assembly in Bend, OR<div dir="ltr" style="text-align: left;" trbidi="on">
Finished the doors and installed them yesterday. Installation went smoothly and doors look and work great!<br />
Pretty much maxed out the space capacity of the trailer - but they rode fine. Got an early start to beat the traffic and to ensure we'd get a parking spot (well, okay, like 6 spots) in front of the store they are installed in. <br />
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Doors installed and fully open. They roll pretty easily, despite weighing nearly 500 pounds apiece. The <a href="http://orionforge.com/">custom hardware</a> works very well, and looks heavy duty and industrial.<br />
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Doors fully closed. Nailed the reveal - 1/8 gap, top to bottom. <br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-91577191987434334822013-05-14T17:41:00.000-07:002013-05-20T07:20:00.555-07:00custom barn doors and track hardware by orion forge<div dir="ltr" style="text-align: left;" trbidi="on">
I've been working on two large steel doors (9'2" h x 8'6" w) for a local retail store in Bend, Oregon. It's been quite a project. I've learned a lot about welding light tubing and sheet; before this project I'd never even purchased 22 gauge steel sheet before, much less welded it. I also have never tried to patina such a large expanse - challenging operation! Doors are mostly complete at this point - still working on building the custom rollers and track hardware and then have to install everything. Doors weigh approximately 475 pounds so moving them is tough.<br />
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Welded .065 wall 1.5" tube frame sheeted with 22 gauge. installed 1.5" rigid foam insulation inside frame to help dampen sound and take some of the drum effect out of the doors.<br />
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After the patina went on, steel trim was installed by stitch welding perimeter and passing some rivets through entire door and plug welding the back side.<br />
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Detail of the steel trim. Dozens of rivets - most of them just for show. <br />
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Heavy duty rollers!<br />
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Long track! Drilling mounting holes on 17' bars meant meant moving the drill press to the middle of the shop.<br />
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Doors feel pretty big when they are stood up in the shop.
excited to see them side by side when they are
installed! <br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-11431776360833049012013-05-04T09:37:00.001-07:002013-05-20T07:25:28.925-07:00Blacksmithing lessons <div dir="ltr" style="text-align: left;" trbidi="on">
Just finished up a series of blacksmithing lessons with Westside Village middle school. I had fourteen (yes, 14!) middle schoolers crammed in <a href="http://orionforge.com/">Orion Forge</a> banging away. We did five, two hour sessions and they produced 8 hand forged wall-mounted coat racks. They plan on selling them at an upcoming auction in an effort to raise some money for a trip to the coast. Super fun, and they did some good work, especially the girls. <br />
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After Westside Village finished up I began a series of blacksmithing classes with the Waldorf school of Bend, Oregon. Only 7 students for this one, so the shop felt downright manageable!<br />
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Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-89581525788200994122013-04-23T08:57:00.002-07:002013-05-29T18:11:27.866-07:00hand forged mirror frame<div dir="ltr" style="text-align: left;" trbidi="on">
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After the scrolls were forged (see post below), I textured the vertical flat bars under the powerhammer. Here is a picture of them textured. I also forged the offsets so that the horizontal bars can pass beneath them and ultimately rivet together.<br />
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All the pieces forged and laid out. Ready for fit-up and assembly.<br />
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Fully assembled and freshly waxed. Ready for glass!</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-60932677876979359782013-04-23T07:47:00.003-07:002013-05-29T18:16:06.987-07:00hand forged mirror frame<div dir="ltr" style="text-align: left;" trbidi="on">
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My latest commission is a large, hand forged mirror. The frame design
is modeled after a stair guard railing that I built and installed
several years ago (pictured below). The mirror will hang near the railing and together
the two will be a solid representation of <a href="http://orionforge.com/">Orion Forge</a>. <br />
Below are a few pictures of my progress so far:<br />
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Initial drawings on paper.<br />
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Design then transferred to layout table.<br />
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I built a jig to ensure all scrolls would be exactly the same.<br />
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Completed scrolls.</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-50921967725165220942013-04-16T15:20:00.003-07:002013-04-16T15:20:58.042-07:00fire pot<div dir="ltr" style="text-align: left;" trbidi="on">
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I found this tank end at the scrap yard with the intent of using it as a fire pot for a recent commission. I trimmed a bit of the sidewall down and sanded the edge, and then torch cut a couple of "cracks" in it to add to the clay artifact look it has. <br /><br /></div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-12949840706592285232013-04-16T15:10:00.001-07:002013-04-16T15:15:29.926-07:00fire pot<div dir="ltr" style="text-align: left;" trbidi="on">
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Forging and fitting the legs to the pot. Each leg is unique, I started with a general idea of how i wanted it to look, and then started bending. I enjoy forging organic forms - these had to match the radius of the pot, but beyond that they could kinda go wild. </div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-41696569207264005622013-04-16T15:07:00.003-07:002013-04-23T08:48:57.902-07:00fire pot<div dir="ltr" style="text-align: left;" trbidi="on">
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The legs waxed and ready to rivet onto the pot<br />
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Riveting complete. Ready for fire!</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0tag:blogger.com,1999:blog-154771857719450343.post-25110996695106042272013-03-10T12:16:00.001-07:002013-03-10T12:17:10.536-07:00found, forged, and fabricated wall sculpture "family"<div dir="ltr" style="text-align: left;" trbidi="on">
Here's the latest in a growing number of the wall pieces I've been building using found, rusted scrap. It measures about 9x14<br />
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The client requested an anniversary gift for his wife. They've got a couple kids so I made the piece reflect family.</div>
Orion Forgehttp://www.blogger.com/profile/18387802142400106108noreply@blogger.com0