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The Client: Conservation Solutions

Forging a new right arm for "Liberty" and restoring the hands of "Justice"

Restoration of  zinc statues from a court house in North Carolina. 

Flag a missing piece:

When I was forming parts for the flag, one got overlooked, a small section that had even smaller parts on different sections of the pattern. (The pattern was made to facilitate removing it from the original, and had little to do with the way the components needed to be made.)

When I fit the top conic section onto the arm and lower flag, there was a hole.

Hmmmmmm . . .

Back to the pattern and make the part. . .
rough formed

The Part is preformed over a ball stake into a curved channel of the approximate size.

This above, is the part after the second forming pass and at right I start tuning the shape towards the one needed.


 Gene forms the channel to close to the required shape.
Pattern tested against shape At far left is a photo showing the part after the 3rd round of  forming. It is close to the needed shape.

I have taped together a pattern copied from the three sections the part was spread across and do a test fit on the part.

 I then trace the part  onto the piece and draw a fudge factor/solder flange line around it to allow for further changes to the piece.

I then cut the part out and get ready to bend it
to fit  in the spot it needs to be mounted.
Pattern traced on Trimmed to fit
Here I have taken the curved shape and bent it to match the existing parts of the piece.  

This happens in stages.
 
Initially it is bent to match tangently in one area , clamped there and then additional bends are made to bring the rest of the part into contact. Often times the part needs to be removed and tuned on the stake to give it the right geometry.

Once the part fits tangent at all points and it is either soldered in place or temporary clamps are installed  so it can be removed and reinstalled  if need be.

In this case we used the cleco clamps because I still had to fit the flag section on and might need to tweek that upper edge to mate better with the large cone section of the flag.
Bent and twisted into position .

more coming
 as we begin the final assembly




Projects : CS : Liberty & Justice : 01 : 02 : 03 : 04 : 05 : 06 : 07 : 08 : 09 : 10

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