The process of making a custom, hand forged fire screen...
	The following is a pictorial essay showing some of the steps required to create a unique and custom hand forged fire screen for a discriminating client...
								<<Left: The client's fireplace opening measured approximately 6 feet tall and 5 feet wide, which required building a frame and two separate doors.  The desire was to match the theme of an existing front door grille so a couple of design variations were submitted.  After final approval, the design was drawn free hand with chalk upon a lay-out table. The frame and doors must always fit well and operate freely so accurate measurements are mandatory but the decorative elements are completed by the smith at the anvil.
			Right>> A piece of bar stock is heated in the blacksmith's forge prior to forming it into a decorative element.  Although modern fabrication is often done with purchased components, the elements in this screen were hand-made and forged from raw stock.  The individual components were later joined with traditional techniques such as forge welding and riveting.
								<<Left: The parts for the bottom portion of one door have been forged and arranged in proper orientation to the chalk outline.  In addition to the typical gray finish of freshly forged iron on the various elements, notations regarding stock measurements can be seen on the work table.  At this juncture, the parts are simply resting in place and have not been fastened.
			Right>> A wider view of the same door showing most of the final components.  After the elements are assembled, the screen is stretched and fastened permanently with rivets and keepers.
								<<Left: A detail of the doors and pull handles after final installation.   Several coats of finish have been applied to preserve the patinas and other highlights derived by hand polishing with various grades of sandpaper.
			Right>> The finished screen frame and doors, installed and ready for use.  The horizontal bar seen in the bottom right panel is a natural gas pipe.  Using our method of installation with 'cramp screws' that pass through the frame sides, the total time spent inside the customer's home to set the frame and hang the doors was about fifteen minutes.
	Copyright: Comal Forge - 2004 All rights reserved.  No part of this site including any original designs may be reproduced, copied or otherwise used without the express written permission of Comal Forge.