Building a pair of wrought iron gates



There are three vertical bars in each gate leaf which extend from the heel bar up to the lower lock bar. These bars are fairly simple, but like everything else on an iron gate, there are many steps in their preperation.    
  After rough cutting the bars to length, a tennon was hammered onto one end. This work was accomplished with a 5/16" spring swage under the power hammer.   The swage leaves a pretty good tennon which is cleaned up with a milling cutter which has a 5/16" pilot hole. This cutt4er is driven with a half inch drill and leaves a good flat seat.  
This is the tennon, ready to fit to the heel bar. The finish length has now been determined and a twist will be added at two thirds of the bar's length. A mark was made with a dull center punch and the bar, heated on the mark. It was then hammered to a thickness of 3/8" and allowed to spread out wider than the parent bar.  
Each bar was given a 3/4 twist localized on the hammered section Three of the bars were twisted with a right hand turn and the other three were twisted to the left  
The final step is to carefully mark the upper ends and hammer the tennons. After fitting the lower lock bar onto the top tennons, every thing was clamped up square and the lock bar was lightly welded to the apron bar. That leaves us with a solid framework for fitting the dog bars.  
  Dog bars are short, often spikey bars which are lacated along the bottom of a gate or fence. Their purpose is supposedly to discourage commerce conducted by dogs and other small creatures.      
  The top of each dog terminates in a ball which is worked up with a spring swage in the power hammer   The peice on the left is right out of the swage and the peice on the right has been tapered back by hand.   This is the power hammer that we talk about from time to time.    
Here are two of the dog bars ready to assenble. The out board branches are 5/16 by 5/8 hammered to a point, The center bars are cut to length. The very ends of each set is arc welded so they won't slip in the fire and everything id fluxed with borax.  
  A tennoned stem is welded onto the dog bars to elevate the scrolls to a point where I can insert the fastening for the side panel scrolls    
Sorry I can't show many of the fun parts but I don't have enough hands. This picture shows the bars after they have been forgrd into one peice.    
Finished dog bar. only 15 to go.    
Here's the whole thing temporarily put together with clamps.  
  Noank Foundry