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 balustrade before restoration.
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
View of the window shutters from the verandah
Custom Japanese style pillar lights for driveway entrance
A recent project required the design of a pair of custom Japanese style Pillar lights for the
entrance to a rural estate. Commercially available pillar lights were too small as the sandstone pillars were over two metres high and 800mm square. To simplify constructing a complete electrical fitting (which includes electrical safety standards compliance and rating) a commercial fitting was selected which was of a suitable style and construction that could be adapted to a larger fitting.
The new Japanese style pillar lights are essentially a lampshade that fits around the commercial fitting. The base section is fastened to the sandstone top of the pillar around the commercial fitting. The lightweight metal roof section is attached to the top of the metal frame of the commercial fitting which has had its glass shade removed.
Below details the steps in building the fitting.
Steel frame of the pillar light. This will be fixed to the pillar top
Translucent acrylic windows fitted to the metal base frame
Marking out shape of the galvanised iron roof
Folding the roof cutout section with sheet metal bender
Completed top roof sections ready for painting
View of the base set around the commercial light fitting
Stainless steel armillary sphere on front lawn
This DecoWorks stainless steel garden armillary sphere fitted to a sandstone column adds a unique and interesting feature to this front garden lawn.
The armillary sphere is 70cm high with the central sphere itself being 45cm in diameter. The finish is raw brushed stainless steel which will last many years exposed to the elements without any corrosion problems. The armillary sphere was shipped to an interstate client who arranged the cutting of the sandstone support column and the fitting of the sphere itself.
More information on armillary spheres can be found here. The sturdy base on the sphere can be easily attached to a support pillar such as this sandstone block or a custom structure.
Stainless steel garden armillary sphere
Another view of the armillary sphere showing its solid construction
Armillary sphere fitted onto new support
A client who had previously commissioned a DecoWorks polished stainless steel armillary sphere recently moved to a new, larger house. They wanted to remove the armillary sphere from the garden wall of the old house
and have it re-installed in the garden of their new home. We were approached to design a new support for the armillary sphere so it could be placed in the garden of the new house.
In keeping with the materials used for the armillary sphere the support was constructed from stainless steel to ensure a long life in its seaside environment. Stained Merbau timber strips were cut and attached to the support framework to form the outer *skin* of the support.
Top of new support
Detail of timber clad armillary support
After the new support had been concreted into position in the garden the armillary sphere simply bolted onto the top. It makes a great focal point in the garden and adds a unique visual addition to an already beautiful outlook.
Stainless steel armillary sphere on new support
Artistic stainless steel window security grille installation
This unique artistic stainless steel security grille makes a very stylish addition to this family home in Sydney. The brief from the client was that she did not want traditional security bars on the front lounge room window because it would feel like living in a cage. In collaboration with the client the design evolved into a sinuous web of leafy vines.
Stainless steel was chosen for the construction to ensure a long and corrosion free life. Using flat bar gave the design a light and airy look while still maintaining a strong structure. More information on the stainless steel security grille construction can be found here.
Detail of the artistic security grille
Stainless steel armillary sphere on garden wall
Here is another installation of a DecoWorks polished armillary sphere. This polished armillary has a high lustre so it sparkles in the sunlight. Each sphere is built for a specific latitude so that the earth axis is parallel to the real world north/south axis.
Further information can be found on the page relating to the armillary’s construction details.
Stainless steel was chosen for the armillary’s construction because this particular sphere was going to Australia’s Gold Coast where the salt spray would destroy any other material over time. This polished armillary sphere makes a fascinating focal point to the entrance gate and will look *as new* for many years to come.
The armillary sphere (from the Latin “armillae”, or bracelet) is a representation of the celestial sphere with the Earth at its centre. It was used by ancient astronomers to describe the motions of the stars and planets relative to the Earth. Their use and development had reached a zenith during the Renaissance. In the seventeenth and eighteenth centuries the armillary sphere was more than ever a necessary accessory of the gentleman’s study or library.
A commercially available custom hinge can usually be found to suit almost any application. However, sometimes a situation arises when a purpose built custom hinge needs to be made. Such a situation arose when a set of Art Deco security doors had to be installed on the inside of some outward opening courtyard doors. The security doors also needed to be able to open out as well or be left locked while the outer doors remained open.
To enable the inner and outer doors to be totally independent of each other they needed their own hinge but they also needed a common pivot so that they would not foul on each other when opened and closed. This was achieved by making a combination butt/parliament hinge where one flap was longer than the other but they both shared a common pivot flap.
The first step was to find hinges that allowed themselves to be modified into a custom hinge. Eventually a quantity of 90mm butt hinges were found that used 3mm thick steel flaps and had removable finial ended pivot pins. Additional parts to make the extended parliament flap were laser cut in 3mm steel. Once the extension pieces were assembled they could be welded to the required hinge flap. Photos of the installed hinges can be found on the completed installation link.
The pictures below show the steps involved in making the hinges.
Parts used to make the custom hinge
Two hinges were first disassembled
Two pivot pins are joined together to make a longer pin to fit the wider hinge
Two hinges are welded together on one side leaving two independent flaps held in place by the longer pivot pin.
Assembled laser cut hinge extension pieces
Fitting an extension piece to one hinge flap
Completed combination hinge
Hinge operation positions