Using some new tools

We recently acquired a tool called a pyramid bender. This tool allows us to roll complex curves in many different materials. As is usual with new tools, as soon as we got it hooked up we used it on a half dozen different projects and can no longer imagine life without it.

One of the first projects we used it for was an awning over a back door over a new construction in Mountain Brook. The material is all 3″x 1/2″ flat bar that we textured heavily on the power hammer with a fullering die specially made for this project.

This is what the texture comes out like. Repeated narrow identities along the widths of the bar, which almost looks like curly maple.

After going through the dies, the flat bar becomes all bent and twisted, so we passed it through the bender a few times to flatten and straighten it out.

We then used the bender to roll the large radiuses that made up the awning parts. The smaller radiuses were formed hot at the forge.

We are always looking for new tools and techniques to improve our capabilities. Being able to quickly make perfect bends allows us to spend more time on other details of a project. We’re always trying to deliver a better, more perfect product. Buying or making tooling is part of that process.
This awning is now being Powdercoated before installation. We will post some finished shots after its up!