Floral Security Door

Completed Security door

This Inner West home in Sydney has beautiful lead light windows in the front door which the owner wanted incorporated into a security door. The main floral motif of the lead light door panel was used as a starting point for the design.

Once the design was completed and approved by the client work started making all the intricate curves from 12mm solid steel bar. The small leaves were challenging to make because of their varied and tight radius curves. There were four separate bending operations needed to make them. Once all the parts were finished they were assembled in a jig on the work bench before being welding together.

The completed door captures the sinuous flow of vines and leaves weaving up from floral blooms.

Laying out design
Laying out the design
Lead light panel
Lead light front door panel

Original front screen door
View looking out from house

Security Door Conversion

Completed conversion

A major renovation on an Inner West semi led the owner to want to replace the existing steel security door. To keep costs down we suggested to retain the existing installation but replace the bars with a new design that reflected the design of the front door.

The front door had a circular glass window surrounded by rectangular glass panels. The door was carefully measured along with the security door and a new design drawn up to reflect the front door.

The existing security door and surround was removed and taken to the workshop where the bars were cut out to accommodate the new design. The frame of the existing security door had been powder coated and this all had to be removed before any work could commence. A quote to get the frame sand blasted was extremely excessive so it had to be done by hand. Tedious but effective.

After the new design had been set up in the frame and welded in place the door was cold gal primed before applying a second primer coat and then two top coats to complete the build.

Cutting out existing bars from frame
Cleaned frame with new design jigged in
Original security door showing open front door

Bespoke Security Door

View of security door from inside house

This Sydney Inner West semi had an unattractive screen door the owner wanted replaced with a steel security door. The front door had an interesting round glass window and glass panels in the form of a cross so we decided to make the design of the security door reflect that of the existing front door.

After carefully measuring the front door a design was developed that would integrate with the front door. It was an uneventful build as we have done several of this style of door in the past.

After laying out the design and welding it together the door was painted and taken to the house and installed. The new door made a massive improvement to the look of the entrance to the house.

New security door with same pattern as front door
The original aluminium mesh screen door

Window Bars Upgrade

ODEON design on double window

The new owner of a ground floor Sydney apartment was very unhappy with the standard window security bars that had been installed by the previous owner. We were approached to make something a little more stylish. Several design options were presented to the owner and it was decided to go with our Art Deco ODEON design.

To simplify the build and avoid putting more holes in the aged brickwork it was suggested to keep the original steel frames and attaching points and simply remove the old vertical bars and replace them with the ODEON design.

The old bars were removed and taken to the workshop where the old bars were cut out. The new design was assembled and jigged into the old frames and welded together.

Because of the exposed position we decided to have the window bars hot dip galvanised to ensure long term resistance to corrosion. Once back from the galvanisers the bars were reinstalled into their original position to the delight of the owner.

Single window ODEON bars ready for fitting to frames
Original double window security bars were not very attractive

Window bars after galvanising
ODEON design on single window

Security Door Redesign

Redesigned security door

I received a call from a client who was renovating their home in an Art Deco style. They had installed a new front door with a porthole window along with small paneled windows flanking the side. The existing wrought iron scrolled security door just didn’t look right.

They asked if we could design a more appropriate security door. The existing security door was is very good condition so I suggested modifying its design to save the expense of having to make a new door.

The first job was to have the old security door sandblasted to remove the decades of accumulated paint layers and surface rust. Next, the old wrought iron scroll work was cut from the frame leaving the central area open. The new design mirrored the porthole window in the door and also aligned with the window frames either side.

The picture on the left shows the new design laid out in the existing door frame. Care had to be taken so as not to distort the frame when welding in the new section as this could cause difficulties when reinstalling the security door back onto its original hinges.

After the new design was welded into place the whole door was given two coats of zinc rich cold gal paint. After the cold gal had dried a metal primer coat was applied in preparation for the top coat. The final two top coats were allowed a week to dry completely before installing the door back on the clients house.

The picture below shows the before and after views of the front security door. The new design is a vast improvement on the original design and integrates very well with the new front door and side windows.

Ashton Security Side Gate

Ashton security side gate
Ashton security side gate

A house in Marrickville had a timber security side gate to stop access down the side of the house. Being timber it was also impossible to see down the side of the house or see someone who may be wanting to get past the gate.

The owner decided she wanted a steel security gate made that had a similar design to the existing front gate of the property. It would also allow her to see who may be wanting to enter down the side of the house.

A dead lock was needed to fit into the steel support rails so the gate could not be opened without the key.

Exisiting front gate
Existing steel front gate

The existing gate (shown on the left) was used as a basis to develop the full height Ashton door design as shown above.

Fitting the dead lock to the steel SHS tubing required inserting 12mm steel plates into the 1.6mm walls of the steel tube so threaded holes could be cut to secure the lock catch attaching screws.

Finished lock attachment plate
12mm steel plate fitted to SHS steel and drilled and threaded for lock catch
securing steel plates
Top and bottom view of 12mm steel plate before fitting to SHS tube

Before and after view of the side security gate

Comparison of old vs new side gate
Before and after security side gate

Art Deco Folding Security Panels

Above shows a test of the opening mechanism of the security panels.

Reagh Bar security panelsThe project involved the design of Art Deco folding security panels to secure the alcoholic assets of a CBD Sydney bar. The Reagh Bar at the Castlereagh Boutique Hotel needed to leave their bar stock on the shelves behind the bar rather than having to put it all away each night and re-stock the following evening.

The Art Deco era Castlereagh Hotel opened on September 12th, 1927 and was built by the New South Wales Masonic Club. It was the first reinforced concrete building in the Sydney CBD and, at the time, was the tallest building in Sydney with 12 floors. Its construction set the precedent for future CBD buildings. It has been the base for the Masonic Club ever since and they wanted something sympathetic to the Art Deco era of the hotel for the folding security panel design.

Our PLAZA style Art Deco design was selected as the optimum style for the folding panels. The design brief was for security panels that could be easily locked and opened and not be too obtrusive. A set of six centre opening Art Deco style panels were designed that satisfied the brief while keeping the overall look light and airy. Clear polycarbonate panels were attached to the back of the folding panels to prevent access to the the bottle stock through the steel bars when the panels were locked closed.

The following photos illustrate the construction of the folding panels. To keep the visual impact of the bars to a minimum 20mm wide framing was chosen. To avoid having two adjacent 20mm vertical bars together making 40mm wide vertical sections 20x10mm solid steel verticals were used which presented a combined 20mm width overall. This made attaching the clear polycarbonate back panels difficult. Since each panel required forty screws to attach to the frames they had to be individually drilled and tapped into the solid 20x10mm sections to accommodate the fastening screws.

The geometry of the six folding panels was crucial and they had to be millimetre perfect so they would meet in the middle of the bar section and lock together.

The top and bottom sections of the frames were hollow 20x20mm SHS steel and only 1.6mm thick so 12mm thick sections had to be fitted into them so the pivots had something solid to screw into.

(Click on an image for a larger view.)

Pivot attaching points

Fitting 12mm steel plates into the top and bottom frame sections to attach pivots

Fitting hinges to bars

Vertical bar section hinges showing open/closed positions.

To keep the overall look light and airy the clear panels needed to screw directly to the back of the 10mm wide vertical bar sections. This required drilling and threading for 240 screws. To simplify construction the panel operation geometry was done before the design was welded into them.

Tapping holes

Drilling and tapping holes for attaching clear polycarbonate panels to frame

Panel geometry

Checking the geometry of the folding panels before fitting the design

Once the panel folding geometry had been confirmed the PLAZA design was jigged into place in the frames and welded in position.

Laying out the design in a jig before welding everything together

Completed side with design in test frame to double check geometry

The clear polycarbonate panels were attached after all the welding was completed. To accurately drill the screw holes in the panels dummy screws with sharpened heads were fitted into the screw positions and the polycarbonate was hit lightly with a hammer over each screw point to indicate where the holes should be drilled. Preliminary testing of the panel operation is shown in the video below.

Polycarbonate panel fitting

Fitting polycarbonate sheets to back of frames

All polycarbonate panels fitted and fitted to test frame to check alignment

The folding panels are supported and slide inside tracking sections at the top and bottom. The bottom tracking can be removed when the panels are stowed open on each side. When closed the panels are secured together with a pivoting drop bolt. The operation of the panels is shown in the video at the end of the post.

Security panels closed

Installed panels closed

Security panels opened

Installed panels opened

Reagh Bar security panels

Front view of closed panels

Front view of opened panels

Ashton Style Side Gates

Centre opening Ashton side gates

Centre opening Ashton side gates

A client wanted custom side gates built for their Art Deco home that would match the style of the original front gates on their property. Our Ashton style was the ideal choice.

The side of the house where the side gates were required was a little wider than normal which would make a single gate too large. Centre opening double Ashton side gates were suggested which would have a more pleasing aesthetic. The fence on the side of the house was too flimsy to support a gate so a 100mm square steel pillar needed to be installed to support one side.

Using the original front gates (which we had just restored) as a guide, the Ashton design was adapted for the side gates to capture the look that was wanted.

One gate layout

One gate half jigged out ready for welding

Side path before gate installation

Side path before gate installation

Completed Ashton gates

Completed Ashton gates with a cold gal coating and primed

Back view of gates

Back view of gates

The installation was very straight forward but the house was cement rendered and there was no way of knowing if you were drilling into bricks or mortar so dynabolts would be a bit dicey. Instead it was decided to use Chemset studs which provided a much more secure anchor without putting undue stress on the brickwork.

The installation of the Ashton style side gates has made a nice addition to the overall look of the property.