This project was commissioned to me by a local wedding decorator. My goal was to create a lightweight, portable, wrought iron sign that was elegant and complemented the wedding theme.
Here are 4 methods used in this video. It may take some practice, but ultimately, the final product is worth it.
1. The Tiger Twist
I start the tiger twist by laying out 6 inches of hash marks on all 4 corners of a 3/8″ square stock. I used a grinder with a cutting disk but you can use a file or hacksaw, either would work.
With the piece firmly secured in a vice, begin heating the metal until it’s red hot. Twist the square stock 45°clockwise using a tap & die handle or a crescent wrench. Move the torch head 3/4″ up the material, heating the metal once again. This time twist 45° counter clockwise. Repeat these steps through all 6″.
This could be done in many different variations by twisting 90°- 180° (even 360°), creating an assortment of patterns. Play with it and get creative.
2. The Halo
Start this by cutting a template out of a piece of 3/4″ plywood. I made an oval in this project, but it could be any desired shape: circle, rectangle or square.
Secure the template to the bench using a couple of clamps. Then tack weld a stop next to the template, leaving enough room for the 3/8″ square stock. The jig is now ready.
Placing the square stock in the jig, pull it around the template while hitting it with a ball pein hammer. You may need to heat the metal to make it malleable.
3. The Bird Cage
With 4 even pieces of metal, tack weld them in this orientation. I used some weld rod in this project. Just hammer off the flux.
With the material pinched in the vice, begin heating at one end. Once red hot, twist the piece clockwise. Progress down the workpiece, heating and twisting.
Heat the center until it is as hot as can be without melting. Now twist counter clockwise while pushing towards the vice, also hammering on the end until the bird cage is formed. Adjust if necessary while metal is still malleable.
4. The Logo
I would have to say one of the most difficult things in this project was matching the font that is specific to the company’s logo.
Using a soap stone, draw whatever it is that you want to duplicate onto a workbench. You can use the floor if the workpiece is larger. Bending the material in small increments, place it over the drawing often to check for fit.
An easy technique for bending the material is using a vice. Pull the piece in the direction you wish to bend, pinching between two points on the vice.
For the tighter radius an anvil could be used by hammering the material into the desired shape. If you don’t have an anvil, a hitch ball or a short piece of railway track would suffice.
If I was to change or do anything different I would experiment with some brighter, more vibrant colors as it is difficult to make out some of the finer details due to the lightweight materials.
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