Oversize Tiffany Style Gift Box

Oversize Tiffany style gift box

Oversize Tiffany style gift box

A dance prop in the form of an oversize Tiffany style gift box was required for a competitive dance routine. The box was to be big enough to conceal the dancer inside and light enough so it could be carried onstage for the routine with the dancer inside. It also had to be strong enough on the top so the dancer could perform her routine on the lid.

For rigidity the dance prop frame was constructed using 12mm hollow square steel with extra braces in the base and lid sections for additional support. To keep the weight as low as possible it was clad in 7mm marine ply which was liquid nailed to the frame. Small hand cutouts were cut in the sides to enable it to be carried and a small lip attached to the front of the lid to make opening it easier.

When the dancer burst out of the oversize box by throwing open the lid it put considerable stress on the lid stays. These were custom made using 3mm flat steel to stop the lid opening too far so the dancer to get out and close it easily. Another 30cm square wooden replica of the oversize box was built to act as a step to facilitate the dancer stepping up onto the closed lid. This was incorporated into the routine to make the transition as seamless as possible.

Tiffany style box opened

Tiffany style box opened

Heavy duty hinge stays

Heavy duty hinge stays to support the lid

Steel Balustrade Railing Restoration

Steel railing restored to its original condition

Steel railing restored to its original condition

This steel balustrade railing had suffered from severe corrosion resulting in many sections of the design being lost making it look unsightly and in need of restoration.

Before the restoration could start custom bending jigs needed to be made so the new sections of the missing design could be fabricated. The new parts and sections were made in 25x3mm flat steel to match the existing design. The corroded sections were cut out of the balustrade railing and the new sections welded into place to complete the restoration.

Damaged section of the steel railing

Damaged section of the steel railing balustrade before restoration.

Removable Window Security Bars

removable window security bars

The Art Deco style removable window security bars

A client wanted some Art Deco style removable security bars for her bathroom windows. Because it was a block of flats she wanted the removable bars mounted on the inside of the windows so that the outside appearance of the building wasn’t affected.

The security bars use a simple ODEON Art Deco design which is mirrored in the opposite window to achieve a more balanced look.

The removable bars are held in position by brackets fixed into the bottom of the window frames and locked in position by two standard window locks attached to the top section of the security bar frames. The bars can be removed by removing the two pins in the locks and pivoting them forward and out of the bottom brackets.

The pictures below illustrate how the removable bars are fitted/removed.

windows before security bar installation

Bathroom windows before security bar installation

Bottom brackets to hold security bars in position

Bottom brackets to hold security bars in position

Detailed view of a bottom bracket which secures the base

Detailed view of a bottom bracket which secures the base

security bars into the bottom brackets

Fitting the security bars into the bottom brackets

Locking the bars in position

Locking the bars in position with the top securing pin

securing pin locked in position

The second bar securing pin locked in position

Silk Flame Campfire Prop

Battery operated silk flame campfire prop

Battery operated silk flame campfire prop

This silk flame campfire prop was made for a theatrical production that needed a safe but realistic campfire effect onstage. Real pieces of timber were arranged around a circle leaving a space in the middle to accommodate a rectangular light box.

The light box was made from ply with several non-symmetrical holes cut in the sides with orange gel glued over them. Two small electric fans were mounted in the bottom of the light box along with three amber 12V automotive stop lamps mounted on the inside of the box.

Three layers of 10mm egg crate diffuser was fitted on the top of the light box to stabilise the airflow and to provide a platform to mount the silk for the flame effect.

Two of the 12V lamps were connected to a flickering candle effect so their intensity varied over time. The fans and lamps were run on a small 12V 9Ah battery. A long lead with a switch was used to control the campfire when it was on stage.

Timber arranged with a space for the light box

Timber arranged with a space for the light box

Top view of light box with the egg crate diffuser removed

Top view of light box with the egg crate diffuser removed

Below is a brief video of the silk flame campfire in operation.

Another Headstone Inscription Repair

Repaired headstone inscription

Completed headstone inscription repair

Here is another headstone inscription repair that we recently completed. In this case the inscription had been painted black and, over time, all the paint had worn away leaving only the engraved lettering in the marble headstone.

The engraved inscription was in very good condition so it responded very well to our repair process which involved cleaning the marble, masking the areas around the lettering, applying a polyester adhesive to fill the engraved lettering and finally sanding off the excess to reveal the inscription.

These steps are described in the photos below and also in this post .

Original headstone inscription

Original headstone with difficult to read lettering due to faded paint infill

Masking tape around lettering

The area around the lettering is masked off for ease of sanding

Applied polyester adhesive filler

The polyester adhesive filler is applied to the inscription with a spatula

Sanding the inscription

Sanding back the polyester adhesive filler with wet’n’dry abrasive paper

Arched Window Louvre Shutters

Arched window shutters

Arched window shutters

An upstairs verandah in a Sydney terrace had a bare brick opening in its side wall which the owner decided needed some louvre shutters. The owner had some discarded louvre doors available and we were approached to see if they could be recycled and used to make a set of louvre shutters for the wall opening.

The louvre doors were cut to size and fitted with arch sections which matched a timber frame that was built to fit inside the wall opening. Once the window frame had been painted it was fitted into the wall opening and fixed in position with black epoxy filler. Epoxy was used because the wall opening was not square and the arched top not a perfect circle arc resulting in clearance variations between the bricks and the wooden window frame.

As can be seen from the photo below the addition of the decorative window shutters was a major improvement to the overall look of the home.

Original opening in the upstairs verandah wall

Original opening in the upstairs verandah wall

Verandah view of window shutters

View of the window shutters from the verandah

Giant Number One

Giant number ONE assembled

Giant number ONE assembled

This giant number ONE was built as a centre piece for a first birthday party. The number stands 2.5m tall and is 1.6m wide at the base.

For ease of transport the number ONE splits into two pieces. Steel pins on each of the four uprights sleeve inside the top part of the frame for assembly.

The framework is made from 20mm steel RHS tube and painted white. A small platform was built into the base to give the option for a high chair to be placed inside the framework. The platform would raise the high chair so it was more central inside the frame.

Giant number one disassembled for travelling

Number ONE disassembled for travelling

Giant ONE display

Giant ONE display installation
(courtesy Serena Cece photography)