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2165 Underwood Parkway
Elm Grove, WI 53122
Contact: David Wareham
Store Hours: 9:00 - 4:00 Monday - Friday (CST)
Deliveries by Freight Carrier must have prearranged appointment!
Freight Delivery Address:
3628 West Pierce Street
Milwaukee, WI 53215
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Jeff Whipkey of SDC Products
17030 West Little York
Houston, TX 77084
sent us this article and photos.
We started this
project like any other, once the job was ready we built a template on-site
using 1/2" x 16ga steel tubing, then we constructed a faux staircase
in our shop to start the work. We used low carbon steel for the entire
railing. Balusters were made of 1/2" round bar that were textured
with our air hammer, top and bottom rails were 1-1/4" x 3/8"
flat bar, newel posts were 1-1/4" round bar also textured with
the air hammer. We new this work would look very busy with the design
so we opted to put the balusters on 6" centers.
Each newel post represents a single grape trunk, so we added 1/4, 3/8
and 1/2" round bar to the base area to show the beginnings of the
root system and used a die grinder to blend them in. This root system
also gave us the platform to mount the railing and help hide the anchor
screws. After the main railing system was welded together we wove the
vines through the balusters, beginning at the trunks and toward each
other trunk. Weaving was random but we kept the building code in mind
so it would pass the 4" rule and we used the leaves and grape clusters
to help manage this. We also have twists and knots through out the vine
system just like the real ones.
Once the railing was complete we sand blasted it. Next we used red oxide
primer followed by a flat black enamel base to enhance the colors we
were going to apply. Gilders Paste™ was used to add the colors
we wanted because of its richness and durability. No thinning was required,
and it was applied using a soft cloth and fingertips. No clear coat
was needed thanks to the hard finish of the paste and we wanted to keep
that "natural look".
had 55 ft of railing. We used 600 leaves of various sizes, 35 grape
clusters and hundreds of feet of vines. We used four different colors
of paste for the detailing and never used all of either color. That
past goes a long way! FYI all the color detailing was applied on site
and after all other trades were finished and gone. An interior trim
carpenter applied the wood rail cap.
was used for the trunks and vines, African Bronze for the leaves,
Pinotage and German Silver for the grape clusters. We had around 400
man hours in this project from start to finish.
Black with toothbrush as a base, Verdigris applied with finger on the
leave stems and leaves, African Bronze was applied with finger on top
of Verdigris on the leaves and Tulip Red on the roses.
Finally, the piece was Powder coated with a clear polyester.
ACME Powder Coating, Elk Grove, IL.
The grapes have been rubbed with Iris Blue and German Silver on top. The
leaves have African Bronze and the bottle has Gold, Iris Blue and German
Silver. The grape vine has diluted Bronze painted and rubbed off to create
a stained effect. Antique Gold was brushed over the stain with a 2"
soft trim brush.
Metal Works, Conway, SC.
Johannesburg, South Africa
The iron casting was sand blasted with fine silica sand and wiped down with
mineral spirits to remove rust, scale, dirt and dust. The base coat on the
leaves and stems is Verdigris, lightly extended with mineral spirits to
stain the casting green using a toothbrush. African Bronze was applied over
Verdigris after 10 minutes with finger, following the direction of the leaves
raised portions. The flowers were covered with Cream using a toothbrush
Canary Yellow applied with finger on a small portion of the petals. Tulip
Red was applied with a stencil brush to simulate stamens. After 12 hours
to allow full drying time, the piece was wiped down with a soft cloth to
produce a shinny to gloss appearance.
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