The gates started with architects drawings, and shortly after paper and cardboard components where made, as prototypes for size, shape and fitting. These were approved and a sample section was made.
With all the details completed, we started the process off, starting with the frame.

Nearly all the components, the scrolls, twists, hat, shield and banner were hand forged by our senior craftsman.
The biggest challenge was forging the banner/ribbon, at the bottom. With brass it can be difficult to fold, twist and forged into the correct pattern.

But it was all created to plan and to time.

We went up to London with the gates for fitting. The hinge design needed careful thought to fit into the Altar side posts and fitting was straight forward. It was then fitted, and polished it up from any marks from transport and fitting.

The whole project was a very interesting for us at Falcon Forge as it uses steel and brass, with lots of forging and creative ability. We are proud of the finished product and our client Russell Taylor Architects and The London Oratory are delighted with the end result.

Here are the Altar gates, in our workshop and also fitted.

Well, there are many different finishes available, and choice will depend on the final use of the item, and the design brief.

Preparation is all important to the finished item- for fine finishes, all welds need to be sanded to leave no discernable marks and all fastenings should be both discrete and neat.

Rustic finish: typically de-greased and treated with tourmaline to give a rustic look, and possibly distressed with hammer, to achieve an authentic look.

Abrasive blasting: to prepare the surface for further finishing. It is done by forcibly propelling a stream of abrasive material against a surface under pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants.

Polished steel: first of all blasted, then a layer of iron paste is applied and then polished off. This gives a softer appearance that gleams but is not weatherproof.

Hot-dip galvanizing: is the process of coating iron, steel, or aluminum with a thin zinc layer, at a temperature of around 860 °F (460 °C). It is widely used in applications where rust resistance is needed, and can be identified by the crystallization ‘spangling’ on the surface. This can be quite a coarse finish. Maybe left to ‘weather’ into a dull gray, or can be powder coated or wet sprayed.

Hot zinc spray: zinc metal is deposited through a Thermal Spray unit onto a prepared blasted surface. If used together with together with a polyurethane paint system, it provides complete anticorrosion protection. The finish is much finer than galvanising for more detailed decorative ironwork and also to give a rust proof finish.

Powder coating: is a type of coating that is applied as a free-flowing, dry powder. The main difference between a conventional liquid paint and a powder coating is that the powder coating does not require a solvent. The coating is typically applied electrostatically and is then cured under heat to allow it to flow and form a “skin.”

Spray painting: is a painting technique where a device sprays a coating through the air onto a surface. This is a simple method with a simple finish.

Two pack epoxy and two pack polyurethane: there are many types for different applications
but it provides a durable, robust finish.

Stove enamelling: stove Enamelling is carried out in temperature controlled ovens and provides a thin layer of durable finish.

And for a touch of luxury …

Gilding: A decorative technique for applying fine gold leaf or powder to solid surfaces such as wood, stone, or metal to give a thin coating of gold.

With our new website we can give updates on our current project and commissions as they happen.

We have added new sections onto our site, and also added restoration projects.

Within the restoration project section we will be showing before, during and after pictures and reports.

Also new for Falcon Forge is our blog spot! We will be updating you on all the news as it happens here at our creation workshop, Falcon Forge.

Also in our blog section will be updates on any shows or events that we will be attending.

We are also on Twitter! Find us by searching for @Falconforge

So please do add our RSS feed, so you can get all of our latest news.

We will be producing a new brochure of lighting within a few months.

In this will be outlining our extensive range of wrought iron, brass and steel lighting and all the possibilities.