Building a pair of wrought iron gates



  There were clearly gates of some kind in the doorways at one time but no photos have surfaced to show what they looked like. These fittings will be used to hang the new gates so all the hinge parts will be made first. The holes in the fittings are nominally 9/16" in diameter but are not nessesarily plumb, they also don't line up with each other. Top and bottom holes measured with a plumb bob showed that alignment was off by 3/8" on average. In order to compensate for all of that, the pintles were lathe turned to 5/8" on one end and then turned with an offset on the other end.      
  Making the pintles was further complicated because I was fixated on using roller bearings to swing the gate on That meant that the hinge barrel needs to be big enough to carry the outer bearing race and that there needed to be some kind of adjustment 'up & down' so that the upper and lower bearing seated together to split the weight load.  
    The hinge pins were turned to carry a one inch roller bearing on top and a 5/8 inch offset on the bottom. both ends were threaded to carry a half inch keeper nut. Barrels were fabricated from a section of tubing with 1/4 " thick bands welded onto the ends. one end was late bored to receive the bearing and the other end was capped and drilled for the top of the hinge pin. Wings were welded onto the barrels for mounting onto the stiles.    
The gudeons are now sized with a bridge reamer and the pins fitted to the holes. Building eight hinges took a large effort and a lot of time, but was nessesary in order to get a solid foundation, plumb and square to measure the rest of the gate from.