new england our 32nd blacksmiths year 1978- to discover...

Winter 2011 page New England Blacksmiths

VOL. 31 NO. 1

New England Blacksmiths

To discover, to help

Winter Edition

Our 32nd Year

1978- -2010

Visit us on line www.newenglandblacksmiths.com

Mark Aspery at the Fall Meet Bird’s eye view of the Fitchburg Forge-In Fall was a busy time for Blacksmiths and the NEB

Inside this issue, Page 2 Contact & NEB Officers 3 The President's Message & A heads up by the Editor 4 Welcoming new members 5 ABANA & NEB forms 6 Hand work– Out of Style?

7 Around New England 8-11 Our Exceptional Fall Meeting 12-13 The Fitchburg Forge-In 14-15 Blacksmith’s Challenge & Handrail Solution

16-17 A Visit to the New England School of Metalwork 18-20 Are You Finished, Yet? 21 A Book Review Tailgate & What’s It

Winter 2011 page 2 New England Blacksmiths

Owen Bostrom- President (12) 99 Chase Hill RD Ashaway, RI 02804 Phone: 401-377-2611 [email protected] .Bob Menard– Vice President (12) 56 Warren Ave. Suite 106 Portland, ME 04103 Phone: 207-878-2217 [email protected] Jim Crothers- Secretary (12) 953 Tuckertown RD Wakefield, RI 02879 Phone [email protected] Leigh Morrell- Treasurer (12) 207 Greenfield Rd Colrain, MA 01340 Phone: 413-624-1200 [email protected] Karen Sims, Membership Chair. (12) 337 Rope Ferry Rd Waterford, CT 06385 860-442-3925 [email protected] Marc Godbout, NH Rep. (12) 170 North Shore Rd. Derry, NH 03038 Phone 603-548-8771 [email protected] Taffy Case, NH Rep. (11) 1789 E. Madison Rd Madison, NH 03849 Phone: 603-367-8225 [email protected] Fred Mikkelsen - RI Rep & Editor (11) 23 Waterman Dr. N. Scituate, RI 02857-2036 phone: 401-647-3086 [email protected] John Nash- RI Rep. (12) 173 Fairfax DR Warwick, RI 02888 Phone: 401-781-0558 The New England Blacksmiths, an affiliate of the Art-ists-Blacksmith’s Association of North America, is devoted to the preservation and advancement of black-smithing. Letters to the editor, articles, technical tips, tools for sale, or other materials which furthers these ends, will be considered for publication in this newsletter.

Most recent Contact information for NEB officers and directors

Thanks to all contributors to

this issue

Judy Berger Judy Boone

Owen Bostrom David Court Keith Leavitt

Neil Mansfield Bob Menard

Leigh Morrell Karen Sims

Next newsletter deadline:

March 15th, 2011

Richard Holman- ME Rep. (12) 195 Varney Mill Rd Windham, ME 04062 Phone: 207-892-9511 [email protected]

Ed Grove- Me Rep. (11) 828 Haley Town Road Brownfield, ME 04010 Phone: 207-935-2262 [email protected]

Courtney Mead- VT Rep. (12) 721 East Hill Rd. North Troy, VT 05859 Phone: 802.988-2503 <[email protected]> James Fecteau- VT Rep. (11) 1735 Main Rd. Huntington, VT 05462 Phone: 802-434-3871 [email protected] Bob Phillips- MA Rep. (11) P.O. Box 583 Westminster, MA 01473 Phone: 978-874-1367 [email protected] Dick Lempici- MA Rep. (12) 2 Lempici Rd Dudley, MA 01571 Phone: <[email protected]> Steve Melady- CT Rep. (11) 54 Cards Mill Rd Columbia, CT 06237 Phone: 860-228-2185 [email protected] Chip Sowalski- CT Rep. (12) 100 Gungy Rd Salem, CT 06420 Phone: 860-287-5395 [email protected] Note: The number ( ) after each name

denotes the year of term expiration of

that Board Member.

The New England Blacksmiths disclaim any respon-sibility or liability for damages or injuries as a result of any design, construction, manufacture, use or other activity undertaken as a result of the use or application of information contained in the newslet-ter of the New England Blacksmiths.

Nancy was explaining why she married Ed instead of Percival. “When I was with Percy, I thought he was one of the most charming, witty and delightful people I’d ever met.” “Then why didn’t you marry him?”, she was asked. “Because when I’m with Ed, he makes me feel like I’m the most charming, witty and delightful person he’s ever met!” Don’t forget Valentine’s Day


President’s Message December 2010 The sweltering of last August has given over to a real December chill this morning. Hello all. We are in the middle of the winter holidays. Christmas is a couple of weeks away, and this is a time of year when nearly every culture has some celebration. I hope for a good season for all. The fall meet held at Brentwood, NH went extremely well due to the great demonstrator, as well as Bob Menard’s organizational skills, good food, and good com-

pany. Even the weather cooperated for the most part. Other than a dead car battery in my truck on Sunday morning, we had a great time as is mostly the case for all meets. Future meets: Bob Valentine is working on the next meet in Goshen, CT. Bob is working out the details, and I’m looking forward to the plans. In the fall we will return to the CT Railroad Museum in Wil-limantic, CT. I understand that Walt Scadden is signed up as demonstrator for that. For 2012 we are working on both meets. One will be in the Lancaster, MA area led by Bob Phillips, and one will probably at Louden, NH led by Garry Kalajian at The Sanborn Mills Farm, which is a new craft center. I am excited about all the new future sites. It adds to the experience to travel to different places. There is also some discussion regarding the potential for another regional event along the lines of the Atlantic Coast Blacksmiths Conference that was held in Ashoken, NY. This remains a discussion in committee at this point. Nothing has emerged from com-mittee regarding any details. NEB is represented on the committee. Leigh Morrell, our treasurer, reported on his progress on bringing NEB accounting to business like standards. When one examines what NEB represents in a cash and materials point of view it is quite im-pressive. When you add the knowledge and ingenuity factor of our collective membership, its willingness to work for the group, and the willingness of members to share, it becomes quite stunning. How can you not be proud to be a part of NEB? A great deal of what I am reading leads me to believe that the economy is on the mend. I know that a lot of you have been doing what you have to rather than what you want to in order to get by. I can report that a few of you have told me that you are busy again. Hopefully, that is the beginning of a turnaround. I’m optimistic, but that is my attitude anyway. I hope that this message finds you in continuing good spirits and good health. Cheers, Owen Bostrom, President, New England Blacksmiths

The Editor Rambles: It was 20 years ago (1991) when I first sent in a contribution to Ed Grove and the NEB Newsletter. That was followed by my first “The Scrap Box” column in 1996 and those continued through the editorships of Ian Walker, Karen Dardinski, Lillian Lovitt and Ralph Sproul. In 2001 I find myself listed as “Temp Editor”, but by the Fall of that year I had failed to escape and was listed as “Editor”. The first special “Scrap Box Issue” was offered in the Fall of 2002 so the count is 45 is-sues (and will be 50 by the end of this year) that have worked their way through my computer, across my dinning room table and through the local Post Office to your mail boxes. With the support of so many of you (and some “pats on the back”) it has been a grand experience. I’ve met many new friends, both here and around the international blacksmithing community and we have a newsletter that reflects the excellent talent found here in New England. But, it is time to move along and let new and fresher ideas make things even better so this 2011 will be my last year of service. The NEB owns the software to create this newsletter and I have a template with the current format available. I will work with the next editor during a period of transition but I really need to spend more time in the shop and less here at the computer. It has been a great run and I would not trade the experience for anything. Fred Mikkelsen, Editor


MEMBERSHIP NEWS Karen Sims, Membership Chair Person

Renewals: We've started off at a better pace than last year. A big THANK YOU to 66 members. Your mailing label will indicate if I received your renewal check before Christmas Welcome these New Members for 2010

Migel Acevedo 55 Bellevue Street S Meridan, CT 06451 203-376-5599 [email protected] Bruce Anderson 24 Brooks St Upton, MA 01568 508-529-6239 [email protected] Jim Argue 144 Somersworth Rd Bollingsford, NH 03869 603-749-2683 [email protected] Colin Belobrow 24 Westbourne Concord, NH 03301 603-229-0464 [email protected] Michael Bergman 20 Ash St Auburndale, MA 02466 617-230-9572 John Borst PO Box 22 Irasburg, VT 05845 802-754-8410 - John Brimson 65 Mistic Ave Rockport, ME 04856 207-230-7169 [email protected] Andy Bryson 7 Pinebrook Rd Nashua, NH 03062 603-891-1402 Laurie Carman 191 Main Street Fremont, NH 03044 603-244-2341 [email protected] Tony Dietz 4 Read Rd Hanover, NH 03755 603-643-3755 Robert Engel 382 West Ghent Rd Hudson, NY 12534 - - Scott M Ferguson 5 Glen Ave Upton, MA 01568-1715 508-529-4446 Steven Gehrke 245 Manton St Lot 243 Pawtucket, RI 02861 401-419-6792 - Jim Godin 1962 Providence Pike North Smithfield, RI 02896 401-527-3767 [email protected] Mark Gordon 4 Rosemount Lane Westerly, RI 02891 401-954-2029 [email protected] Rusty Griffin PO Box 82 N. Chatham, MA 02650 508-776-0265 [email protected] Phillip Guerin 110 Ferry St Lawrence, MA 01841 978-688-2064 [email protected] Patrick Heaney 30 Maple St Apt A Orleans, VT 05860 802.754.8724 [email protected] William Howard 21 Rifuma Way Norway, ME 04268 207-743-7806 [email protected] Edwin M Howard 136 Main Street Essex, MA 01929 978-678-7282 [email protected] Wayne Huberdeau 252 North Raymond Rd Raymond, ME 04071 207-998-1035 [email protected] Michael Imrie 480 Oak Circle Colchester, VT 05446 802-655-5712 [email protected] Mark Jacobs 270 Bonny Eagle Rd Hollis, ME 04042 207-727-4520 [email protected] Sibel Karchner 110 Sadys Lane East Falmouth, MA 02536-6261 508-540-8514 [email protected] Robert LaVoie PO Box 1476 Andover, MA 01810 978-423-1491 [email protected] Jacob Lefton 24 Mountain View Circle Amherst, MA 01002 781-439-1203 [email protected] Scott A Legualt 27 Sagamore St Warwick, RI 02889 401-921-0023 [email protected] Mike Lessard 18 Chapel St Apt 11 Dover, NH 03820 603-509-0688 [email protected] Seth D Levine 569 Middle Street Portsmouth, NH 03801 973-903-2308 [email protected] Lois Lew 222 Laclair Lane Barton, VT 05822 802-525-9502 [email protected] Ed Lutjens 16 Todd Lane South Portland, ME 04106 207-329-0665 [email protected] Willard Magoon PO Box 177 Brandon, VT 05733 802-247-8881 [email protected] Kevin McLoughlin PO Box 51 Rochester, VT 05767 802-767-3030 [email protected] Dennis Morin 103 Marshall St Tewksbury, MA 01876 978-851-6122 [email protected] Cory Morini 44 Little Falls Bridge Rd Rochester, NH 03867 603-206-0587 [email protected] Larry W Orlando 11 Albert St Westerly, RI 02891 401-596-9796 [email protected] Jim Pepin PO Box 2178 Teaticket, MA 02536 794-521-8373 [email protected] Daniel Piotte 276 Choate Rd Enfield, NH 03748 603-632-7242 [email protected] Francis E Poole III 232 Park Circle South Attleboro, MA 02703 508-399-8151 [email protected] John Rais 1063 Mohawk Trail Shelburne, MA 01370 570-228-1029 [email protected] Josh Roberts 16 Kelliher Rd Barrington, NH 03825 603-335-8398 [email protected] Robert E Roemer 185 Main St Bolton, MA 01740 978-779-6954 [email protected] Harry Roop 248 North Rive Rd Lee, NH 03861 603-659-4068 Larry Salate 382 Prospect ST West Boylston, MA 01583 774-262-3939 [email protected] Thomas J Sangiolo 40 Cherry St Plymouth, MA 02360 508-746-2815 [email protected] David Simmons 275 Weymouth Rd Morrill, ME 04952 207 -342-5629 Joe Solmos 32 Almonte Ave Yarmouth, ME 04096 707-847-3466 jsolmos!maine.rr.com Justin Tefft 455 Main St Ashaway, RI 02804 401-315-0265 [email protected] Jeff Toman POBox 83 Mt Desert, ME 04660 207-244-3937 [email protected] Dirk Underwood 9 Lyman Ave Hudson, MA 01749 978-360-0629 [email protected] Joe Vachon 497 Groton Hollow Rd Rumney, NH 03266 603-728-5483 [email protected]

Please e-mail corrections to [email protected]


Please help us by renewing on time and supplying us with current information, Thanks!

New England Blacksmiths Membership Form: [Please check box for renewals or new] Dues are $20.00/yr (Canadian $20.00) payable January 1st of each year Send checks to: Karen Sims, Membership. 337 Rope Ferry Rd. Waterford, CT 06385 Check New or Renewal for 2011

Name

Business name, if applicable

Address Phone ( )

City ___________________________ State__________ Zip___________ Fax ( )

E-mail

Occupation__________________________________________________ Year of birth

Check forging skill: ___Beginner ___Intermediate ___Advanced

Blacksmithing areas of interest

Check all that apply:

___Teach Blacksmithing ___Teach Related Metal-working Skills Which skills?

___Do Public Smithing Demos ___Demo Fee (Amount:_________) ___Require Travel $

___Would hold NEB Office ___ABANA Member

Where did you hear of us?

Use another sheet to comment: (How are we doing? What would you like to see us do?)


The Lost Art of Building With Your Hands by Mitch Albom (from Parade Magazine, non-profit use requested from the author) The kid had an idea. He didn't have money. He didn't have supplies. All he had was a book with pictures. He went to a junkyard, found a bicycle rim, PVC pipe, an old tractor fan. And he did something many of us used to do. He used his hands. He bent. He hammered. He glued. The kid's name was William Kamkwamba. His idea was to make a windmill, be-cause a windmill could make electricity, electricity could pump water, and water could grow crops for his drought-plagued village in Malawi, in southeast Africa. "Normal people do not collect garbage," he admitted, laughing. "The people in my village thought there was something wrong with me." But three months after he started, he'd done it. Made a small windmill with enough energy to power one light bulb. He was 14. When I spoke with Kamkwamba, now 22 -- the subject of the best-selling book The Boy Who Harnessed the Wind -- I was impressed with his ingenuity. But I also felt a pang of concern. That same day, I'd read about the advent of 3-D tele-vision. I worried about our kids, sitting on the couch, wearing funny glasses, all the imagination done for them. I worried they are losing what Kamkwamba found: the joy of creation, of dirty fingernails. It's mostly done for us now. We download. We boot up. We plug and play. We call tech support. And it starts younger and younger. The world of Wii and PlayStation has rendered building blocks laughable. Who needs blocks when you have a joystick? I remember, as a kid, building a beginner's darkroom in our basement (getting instructions, like Kamkwamba, from a library book). I shook film in a plastic canister. Slid paper into a tray of smelly chemicals. It took hours. But eventually, I held a wet print in my hands. Today, my 3-year-old niece, when you snap her picture, grabs for the camera and says, "Lemme see." In her world, all photos are instantly viewable on the back. Now, I don't want to play Cranky Man to technology. But there is a time to discover what you can make on your own. What kid, when we were younger, didn't have paint, tape, or magic markers? A ball of rubber bands? A father's toolbox that you weren't supposed to get into? What kid didn't, at least once, go to the hobby store and buy a plastic model to assemble? Remember that word? "Assemble"? We built little airplanes. We glued plastic ships. We hammered nails (and our fingers), we made forts, we strung tin cans, we drew faces on socks and pulled them over our hands. And through it all, when we held up the toy rocket or the puppet, there was quiet. No thumping music. No sound ef-fects. We growled the noise of an engine, we spoke the parts of our characters. We used our own voices. And in doing so, we discovered them. It was quiet when Kamkwamba tinkered with his windmill creation. Just him and his spare parts. He was too poor to attend school. He knew nothing of texting, e-mail, or the Internet. "The day I connected the generator to the windmill, the whole village came to watch," he said. "I was scared that if this thing is not going to work, then the people who think I'm crazy will prove me crazy." It worked. The village cheered. That led to bigger windmills -- and finally a water pump. But it is fitting that the first thing Kamkwamba powered was a flickering bulb, the symbol of an idea. Because children should know that the most rewarding lights of their lives will always be lit -- not by microchip processors, but by their imagination. Your Editor asks; Is there some way you can help preserve our “hands on” craft of imagination to reality?


Around New England Massachusetts Cabin Fever Meet at Ray Ciemny’s Shop. 54 Fitch Bridge Road, Groton, MA. March 27th 9-4. Be amazed by your friends and colleagues. Show what you know. Ray will show a nifty slitting and punching setup on the fly press. Share a trick that you picked up along the way. Forge and anvil will be available. Space limited. RSVP [email protected] (978) 448-0028

Connecticut January 30th CBG, Southern Bunch and friends at the Driggs Blacksmith Shop on the grounds of the Mystic Sea-port Museum. 1—4 pm Always a good time and you get to tour the grounds a bit before the meeting. Contact Bill Scheer, 860-536-0679 for directions and the free entry procedure. May 20th to the 22nd the NEB Spring Meet At Goshen, CT (just west of Torrington) Hosted by Bob Valentine and his “quartet” check our web site for information as it develops. Members interested in helping Bob can call him at (860)491-2371 We’ve had a couple of good meets at these fair-grounds, in the past and no reason why we won’t again.

New Hampshire March 26th The first open forge day at the NEB Teaching Center Contact, Cory Conway, (603) 929-3536 and check to see that the snow drifts have been cleared enough for you to get there. (Just kidding, we know it will be OK)

Brentwood North– Portland, ME February 26th at the Ball & Chain Forge in Portland Maine. The program will run from 9A to 4P. Coffee, break-fast goodies, and lunch will be provided. For those who have not experienced this program it is four 90 minute stations thru the day. Students complete a project at each station that they can take home. Every 90 minutes the entire group rotates clock wise to a new station and a new project. The cost of the day is $70.00 with all funds support-ing the Brentwood Teaching Facility. Sign up early as there are only 8 spots on a first come first served basis. This 2 to 1 ratio gives the best learning envi-ronment. Payment up front guarantees your spot. I am also soliciting instructors to help out this year. All you need is one 90 minute subject that you can share with others. You don't have to be a profes-sional or master. Many of us have something that can be shared in this type of program. This is a learning process for all especially the instructors. Join us for a day of serious blacksmithing. Contact Bob Menard Ball & Chain Forge 56 Warren Ave. Portland, Maine 04103 207-878-2217 [email protected]

Rhode Island February 26th Southern Bunch, CBG and friends at the blacksmith shop on the grounds of the South County Museum in Narragansett, RI. A little show and tell plus a lot of tall tales and outright lies. An opportunity to show a trick or two.10am—4pm Contact Jim Crothers, 401-789-8290 so we’ll know how big a stew pot to put on the stove.


NEB FALL MEET WOW ! ! !

If you were there- then you know what I mean.

If you weren’t there- chances are you will never understand.

Friday night was the chance to understand practical metallurgy as only Mark Aspery can present the subject. Common words and easy to understand comparisons that make it seem like the recipe for boiling water. (I bet you can do that!) Only Mark would think to use a can of Dinty Moore beef stew (by appealing

to a blacksmith’s appetite, priceless) in modeling the changes as steel is heated and cooled. Along with that we got a whirlwind tour of Italian iron work both historic and modern presented by Bob Menard and photographed on his recent trip abroad. What a way to kick off a meet! Fortunately we were able to give you a pre-view of Mark’s presentation at the forge and with Gerald Boggs (seen below) tending the coke fire things got going early on Saturday morning.


Mark’s motto of “Make first the tools you need—then the project” was where it started as he made the slitting chisel for the ringed cross that we all waited to see.

Then on to the why’s and how’s of slitting verses punching, up-setting and drifting flat and on the diamond.

Always time to go to the board and graphically explain what would happen next and why and even why not because, at times stuff happens!

All this interlaced with anecdotes of his life experi-ence and lessons learned.


A classic scrolled element with water leaves was the second major project that we were treated with.


Green Coal and John D’Abate saw the usual action and some extra efforts as a few people “practiced” on projects for the Fitchburg Forge-In competition.

The membership meeting and election of officers. Congratulations to incumbents and newly (coerced) elected to the BOD! Bob Menard had assembled one of the most efficient meet crews and that only made the weekend the more satisfactory for all involved. To: Bob Menard and company, 9/23/10 Thank you all for a wonderful time, last week-end. Even with a "lesser" demonstrator it would have been enjoyable but with the likes of Mark Aspery it was a meet that will stand out in perpetuity. An organization only lives when new blood is produced for its veins and so we have a long life ahead. We must welcome new folks and not just tolerate them. Our expanded commit-ment to Green Coal (thanks to the dedication of John D'Abate) is a good sign. I will quote from my diary entry of 21 years ago, "Paid my dues and joined up with this great bunch of friendly folks with a capacity for sharing that is unsurpassed." My we always be so, Fred Mikkelsen

The Pancake Breakfast of Sunday Morn

Sibel Karchner under John’s watchful eye.


Images from the Fitchburg Forge-In It takes more than a cold wind to Stop the competition!

Bob Phillips once again took on the task of being the local connection with Achla Designs, the City of Fitchburg and the Massachusetts Cultural Council and then being the MC for this years event. The 7th in a tradition of demonstration and competition in north central Mass. I observed a couple of NEB members competing in the more advanced categories but the Assabet Stu-dents and Neil Mansfield are our favorites!


There’s a slight chill in the air, New England’s trees are proudly showcasing their true colors, the pumpkins have been picked and placed on the door steps, Halloween is just around the corner, and the students from Assabet Valley School are thrilled that it’s Autumn and Autumn means it’s time to be moving hot iron up in Fitchburg, Massachu-setts. Once again Assabet Valley’s Metal Fabrication program took home the championship; Rachel Auger a female jun-ior was thrilled with her winnings of $500.00 Yesterday, the students arrived at Assabet’s Metal Fabrication shop much before the sun has risen, and still with sleep in their eyes, only to load up a school van and a pick up truck with heavy tools, shop equipment, and iron bars before 6:30 am, then driving up to Fitchburg’s seventh annual Blacksmith Competition hosted by Achla Iron De-signs located in Fitchburg, Mass many thanks go out to Achla and her sponsors for giving us an opportunity to com-pete in this unique vocational hands-on event. Well it was a quick stop to a local coffee shop to fuel up at sunrise, then onto what the students have been antici-pating for weeks, the Forging competition. As we arrived on location, the students quickly unloaded the equipment & tools and set up their stations while on standby and poised and ready to go. As the instructions were passed along to each competitor and then bell rang out to begin the contest. The students went right to work and I mean work. It was nonstop action with such a beehive of energy for each forging session. In all, their were three sessions for the event, which included one hour periods for session one and two and then the last session was a two hour period. This year George Martel was the chief judge and lunch time demonstrator. George runs and operates a full time ornamental blacksmith shop in Seekonk, Mass. During our lunch break George forged several beautiful brass flow-ers that were quite impressive, we are happy to have such a fine craftsmen at our event. Our welding hats are off to you George Thanks. This year Mr. Garcia and his metal fabrication students from Old Colony High School arrived in force to compete and give it their all in this year’s event. They were a warm friendly bunch of metal heads… At the end of the day, several Assabet and Old Colony Vocational School students won ribbons and cash prizes. But Rachel Auger was the over all champion for 2010 it was a proud moment for Rachel we are so very proud of her and all of her accomplishments. It’s been a tradition, to treat the students to ice cream to top off a hard days work. Job well done Assabet ! Neil Mansfield, Lead Instructor


Sometimes, a man’s got to do what a man’s got to do by David Court

I was recently asked to build and install an exterior railing. When I arrived to view the site I discovered the contractor had cored the granite steps and installed 1” square posts before the wife said it looked too commercial.

My job was to come up with an alternative. I recognized the situation right away; I was the meat in a husband-wife sandwich. My proposal was to build an organic faux tree railing with curved branches as sup-ports. The square posts had to go. The contractor (who was also the husband) offered to remove them and re-core the holes but I said no as I might be able to use them and I dislike redoing work that was well done. As it turned out they were very useful and I would consider using this

method in the same manner should a similar project come along. I will explain. The stairs curved slightly so I took the cord of the curve using string and measurements (the old way) off of the posts. I went back to the studio where I pressed the 1 ½” pipe nearly to the required bend. The curve was variable so I slightly under bent the curve with the expectation of final forming on site.

To facilitate the bending on site I forged 4 clips for the pipe that are self explanatory by the pictures. The ability to open and close the clips was achieved by cutting the eyes 2/3 through so they could flex. The clips were useful in three ways. First: They allowed me to clamp the pipe using the existing posts to help bend the rail to true.

Second: (picture on page 15) The handrail was then shifted to the outboard side of the posts using the same clips. This allowed for the fit-ting up of the supports to the rail while also aligning to the bottom of the existing post. The intent was to have the branch supports short, then cut the 1” post where they intersected and weld together.


The pre-forged branch supports were fit up and welded to the rail on site and the 27-foot rail was cut in half before transport-ing back to the studio. Once back at the studio all welding, texturing and grinding was done to blend the branches to the rail. On site the two components of the rail were clamped in place outboard of the existing posts excepting the bottom 1” square post, which was severed. The round terminus of the branch support was aligned over the severed post and clamped in place using the clip as shown. (use three)

The support was welded to the stub and blended using abrasives. Next we moved to the third post, cut the 1” square post and aligned the branch over the stub and welded it. Then we moved back to the 2nd support, welding it and finally to the last sup-port. To complete the as-sembly the joint where the rail had been severed was welded and blended.

“All’s well, that ends well”


The Dormitory and Kitchen at New England School of Metalwork By Keith A. Leavitt “To discover, to help”… In keeping with NEB’s motto, I made a discovery last summer that begs to be shared. Coming right to the point, I made an impromptu visit in July to the New England School of Metalwork in Auburn, Maine.

I had hoped to introduce a friend to the direc-tor, Dereck Glaser. As timing would have it De-reck was not available that day, but Susan Madacsi, instructor in residence, gave us a tour of the new on-campus dorm and kitchen.

At right, visiting artist blacksmith instructor Susan Madasci shows visitor Corbin Brace a botanical piece from her ‘bag of tricks’ before giving us a tour of the new dorm and kitchen at the New England School of Metalwork. For nearly 10 years the superbly equipped metals school has offered a rotation of some of the best metals instructors in America. “Bang for the buck” has been admirable, in that the cost of tuition is comparable to other programs. The down-side, as I see it, has been the cost and inconvenience of dealing with motels, restau-rants and time spent driving during off-class hours. Long story short – from observations during my stop-in visit and from testimonials by actual former students

and instructors, I believe the lodging issues have been ad-dressed. To find out if the school’s ad (“Eat and sleep metalworking—very affordable rates”) in ABANA’S The Hammer’s Blow, was as pitched, I asked former students and instructors who had used the facilities to write a few words about their experience with the dorm. Instructor Randy McDaniel writes: "I was very impressed with the new dorm at NESM. One of the finest places to stay on the craft school circuit. Comfortable beds, large bathrooms with never ending hot water showers, color television and well equipped kitchen downstairs. Plus it is right next to the shop. For the con-venience, comfort and cost I don't know why anyone wouldn't stay there!"

School shop with dorm at right side

The lounge


Instructor Susan Madasci (Pictured with visitor Corbin Brace) responded: “The new facilities are a welcome addition to the school and it made it so much more convenient and personal to stay there.” Seen at right, a typical bedroom Student Ian Walker writes: “The dorm increases the appeal of the New England School of Metalwork in several respects: cost saving, con-venience, potential evening access to the shop, an added chance to get to know other students, and healthier eating. Our instructor stayed with friends, but was there for us on two evenings to open the shop and work with us as needed, and the shop was available for use a third evening during a welding class underway at the other end of the building. Those three evenings in the shop were a big plus. There's a supermarket within easy walking distance of the shop and I took advantage of it to get breakfast and lunch fixings. As a consequence, I ate better, for less, and saved time. A bunch of us went out to dinner together and another time I'd do some of that, but "Healthy Choice" meals and a microwave are an easy alternative, though that would go better with company. Overall, the dorm was comfortable, with a great shower and lights that are activated by motion detectors -- both very nice features at the end of a long day in the shop.”

So if you are among those who have questioned the lodging ar-rangements, perhaps my “discovery” will “help” in your decision with regards to taking a class at the New England School of Met-alwork. Happy hammering. Keith A. Leavitt

Gents facilities


Are you finished yet? By Bob Menard We work with a material that once the project is complete, if we don't protect it, it immediately starts trying to revert to its basic nature, ferric oxide, rust. Most projects are not enhanced by this process so we seek to thwart it by using a myriad of different coatings. For items created to be used indoors in a climate controlled environment this is not such a difficult task. There are numerous techniques to accomplish this and they are not the subject of this article. I produce many architectural projects, gates, railings, and fences in my shop. Protecting these products from the environment is important for the appearance and longevity of the piece. I am often surprised by how quickly a fence deteriorates without basic maintenance. Conversely, even half hearted attempts at painting can allow a piece to survive many years. When I first started my business 20 years ago I had a desire to control all elements in the manufacturing process. This included the finish, I had mixed success. This is some of what I have learned along the way. Much of what I make and install is sited in a maritime environment, close enough to the ocean so it matters. The only thing that protects is encapsulation. Paint, the color, is just for looks. It does help protect but it is what is underneath that is really doing the job. Preparation and primer win this eternal struggle with rust. Of course regular maintenance can substitute but it is a rare client indeed that has any interest in taking care of their expensive ironwork. "It's ironwork. Doesn't it just last forever?"

One of the difficulties with large projects is removing mill scale. Everyone will tell you that to get the best finish it must be removed. Well that is true, but I have a number of older projects out there where this scale was not removed and it is not significantly degrading the finish. It is generally stuck on pretty tight. Still the best finish is after the scale is removed. On the big jobs that means sandblasting. I hire that work out. The last time I sandblasted in my shop was 10 years ago. I created an area with drapes to help isolate the mess and had at it. I still find black beauty in funny places all around the shop from that job. Whether you take the mill scale off or not, the most important first step is a great primer job. This is the step that will give the longest life to the top coat and the ironwork in general. The primer I use if I am painting a piece is hardened auto primer. This is a two part product that is quick drying and very durable. Temperature and humidity play a significant role when you are applying your own finish, mostly humidity. This is the toughest to control and high humidity can negatively affect the durability of most paints. Both low temperature and high humidity can also significantly lengthen the drying time. We have an isolated paint room to spray that can have its own internal climate regulated to a fair extent. I apply at least two coats, starting with the work upside down. I find that using that technique generally gives the best looking finish on the show side as the last coats are applied with the work upright and it is already nearly 3/4 finished. I have seen the technique where two different colors of primer are used for subsequent coats. It makes it easier to see missed spots. The top coat is more of a challenge than it used to be. New rules regarding solvents and VOCs, (volatile organic com-pounds), have virtually removed oil based paints from the market. Latex and unhardened urethane based paints are what is available in today's market. Their biggest drawback is they are soft and the urethane paint can take upwards of 30 days to cure. A good alternative is auto paint. It is hard and durable but runs about $125.00 per gallon, reducer and hardener included. If you are looking for a flat or semi gloss finish and additional flatten-ing agent must be purchased and added.

A final consideration when applying your own finish, as you are protecting your work protect your lungs. Canister style respirators are not a luxury when working with these chemicals. Overspray can fill your shop and damage your health.


All these described challenges have encouraged me to look for other solutions for finishes. One I use often is powder coating. This is something that is hired out and has one very distinct advantage, convenience. I drop a job off and a week later I pick up a beautifully coated piece. Of course this is not without its own issues. The process starts with sandblasting the whole piece or rail-ing system. The powder is a spray applied using an electrostatic process. The work is energized and metal in the powder allows a "wrap around" effect to get it on all the surfaces. Then it is put into an oven and the bak-ing process melts the powder into an exceptionally resil-ient plastic coating. It is very tough and resists dings both during transport from the plant to the job site and during the install. There are still multiple coats starting with a primer. For exterior applications they use a zinc primer as the base coat to further inhibit rust. The difficulties with powder coating are different than with paint. The material is plastic and slippery so touching up with paint is not easy. You can not modify your work without breaking the encapsulation. And if you do have to make any modifications it is enormously difficult to get the powder off, even small areas. It resists sanding and it gums up grinding wheels. I have found it easiest to create the project and pre-install it prior to having it coated. I make sure it all goes together and I oversize the holes. Powder adds considerable dimension and it closes up small holes. Threaded holes can be protected by the coating company with silicone plugs and where I can get away with it I leave screws in holes and have them powdered in place. The only time I have had trouble getting them back out is if they get powder baked on both sides, like a fastener through a flat bar. Due to the amount of pesky hand work, having fasteners sepa-rately coated is quite costly. A batch of screws can cost more than the railing. I found that out the hard way. It is very important to have a way to hang the work. It has to be hung to be coated and baked. For some pieces that is self explanatory but for others a dedicated threaded hole for a fastener is needed. My powder firm pre-fers to shoot the work upside down so I always look at the final product with that in mind Powder's biggest weak point is it is not good with nooks and crannies. If there is what looks like a minor seam or void space the powder probably won't get in. It does not flow like paint, either when being sprayed on or baked. Complicated pieces are nearly impossible to completely coat. You have to be aware of areas at the ends of balusters and other joints. They must be completely welded over to seal them up. Otherwise rust can form in these areas. Stuff that is traditionally joined will not seal up with this finish. If you have hollow components, powder can not protect them and rust bleeding from weep holes will occur. For the right project, powder coating is a good solution. If I factor the cost of paint and the time it takes to do a good job, powder coating is cost competitive over doing it myself. I like the convenience factor as well.

The finish that has worked the best for me over the years

is hot dipped galvanizing. Once the zinc is applied, then

it is painted with a two part urethane paint by the galva-

nizing firm. This is corrosion protection at its very finest.

The molten zinc gets into every nook, cranny, hollow

space, post, etc. It also is durable beyond description.


About 5 years ago I installed a gate/fence assembly nearly in the ocean, really barely above the high tide line. It was attached between 2 cliff areas. A large storm blew through and the resulting surf lifted a 1000 lb rock and launched it through the system. It struck with such force it tore 10" of cliff from both sides as it obliterated the an-chor points. The gate and fence parts rolled around in the ocean for 2 more days. I retrieved the steel and brought it back to the shop. The fence sections were bent and twisted, now scrap. The gate was not destroyed but could no longer be used on this site. It has sat in the service en-trance to the shop since, waiting maybe to be used in the future. The paint was considerably dinged up on the whole system but even now no rust has formed anywhere on the

salvaged parts. Where it is stored is not climate controlled and I never made any attempt to rinse the North At-lantic off it. That continues to recommend this finish for me. The process starts with a dip in acid. Then it is rinsed, neutralized and dried. It is dipped in a large vat of molten zinc. Once it has cooled and solidified it is lightly etched and painted. It also has some similarities to powder coating. The coating adds a lot of dimension and weight to the work. It fills smaller sized weep holes. It fills every threaded hole and it makes tight fitting parts unlikely to go back together. It is hung off racks as it is dipped so if holes they can use are not available they must be added. Planning for these eventualities mini-mizes their impact. As I am creating work that is getting galvanized I constantly remind myself to use slotted holes on tabs, oversize all attachment holes, drill 5/16" weep holes, drill extra weep holes, and never leave a blind ended hollow space without a weep hole. Oh and by the way, did I mention the weep holes. I once ended up with part of a railing section that weighed 70lbs more than it should have from one missing weep hole. That one is never going to rust! Think of the weep holes as drains and a way to keep trapped air from preventing complete coating of all components. If I am butting pieces together I make sure I leave a 16th to 3/32 gap dur-ing pre-assembly to simulate the finish build up. Pre-assembly on the site is more critical with galvanizing due to the toxic nature of the finish trying to make changes with heat afterward, i.e. welding or cutting. With large complicated jobs I use bolts and threaded holes to assemble. That way I can make the components small enough to be weight manageable. The downside is every threaded hole must be re-piloted and re-tapped. There is no way around it so plan for it. This is also a good time to recheck the necessary weep holes, the ones needed for the longevity of the product. They may need to be opened up again. I use a smaller size bit from the original hole to try and keep the edges of the hole encapsulated. I always use stainless steel fasteners for as-sembly to avoid future rusting issues. Don't forget to factor that cost into the quote. The current job I have out for galvanizing is 600' of hand rail with separate posts. There are 183 loose parts. To get it all back where it belongs requires an elaborate coding system. I have found a combination of roman numerals and drilled dots to work best for me. Any mark that is made is made deep! I'm talking 3/32 to 1/8. The finish can easily cover lesser coding and then you have a mono chromatic jigsaw puzzle with no picture to go by. The paint is not as durable as powder coat but it is much easier to touch up. They have always supplied me with some touch up paint with the order. If it is not offered, ask for it. The cost of a galvanized finish today is $1.81 per pound of your product with an $800.00 minimum. The cost is usually driven by the market price of zinc. I am sure if I was a much larger client the price would be less. After being surprised once I always get a written quote and pass the cost plus hassle fee on to the client. Some jobs can only be protected by this finish. If I have a client who never wants to do any maintenance to their fence/railing/gate this is what they get. I feel comfortable giving it a lifetime guarantee as I think it will outlive me. When I first got started blacksmithing and fabricating I had no idea coatings could be the challenge or ex-pense they are. It can easily take as long to do a good coating process as it does to produce the work.

Now I know that it is only finished once it has the finish ! ! (and now you know too, Thanks Bob for the informative article. FWM, Editor)


“Boone Wrought Iron” Products and Practices By Don Plummer with Photography by Nick Vincent ISBN: 0-9709099-5-0

In Louisa, Virginia there dwell two of the most wonderful folks in the world of fire and hot iron. One comes from a long line of blacksmiths going back many genera-tions and the other is a transplanted Yankee. They go by the label of Judy & Dan Boone and host the annual “Pasture Party” at their home and shop each late winter to keep neighboring smiths from suffering too much with cabin fever. This EVENT (capitals used for emphasis) attended by many wide ranging smiths, is a combination of learning, laughing and lifetime friendships. If you ever get a chance, to attend, don’t pass it by.

This book showcases their family business and what they’ve learned about marketing, people’s tastes and how to react to the current trends. Well worth adding to your library, heck with the great pictures of Dan’s work you could even leave it on the coffee table in the living room! At right, This is not an OR! This is Dan’s shop! Fred Mikkelsen

Member Judy Berger and The Blue Moon Press Would like you to know of the re-printing of these fine out of print books. 'THE BLACKSMITH'S COOKBOOK' - by Francis Whitaker $40 'HOOKS, RINGS and OTHER THINGS' - by Frank T. Barnes $42.95 'SAMUEL YELLIN Metalworker' - by Jack Andrews $52 Judy also stocks the Boone book mentioned above.

Visit her web site for an excellent selection and opportunity to expand your library. (www.bluemoonpress.org)

Morrell’s Whatsit Is it a tool, a part of a tool? No one has guessed close enough to declare a winner, so one more chance! Measures 9” in length. If you know, or want to guess, send your answer on a 3”x5” postcard, or email [email protected]. The winner will be drawn from the correct answers. The winner will receive either 20 iron-in-the-hat drawing tickets or a one-year membership to NEB! Look for the answer and the winner in the Spring Newsletter. Wholly sponsored by Morrell Metalsmiths, Ltd.

new england our 32nd blacksmiths year 1978- to discover...

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