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Ornamental and Miscellaneous Metal


The official publication of the National Ornamental & Miscellaneous Metals Association

Join us for

November / December 2011 $6.00 US

METALfab 2012, Orlando

National Ornamental and Miscellaneous Metals Association

54th Annual Convention & Trade Show Moving Forward in a Changing Economy

Show guide, page 15

Shop Talk

The aluminum advantage, page 34

Shop Talk

Forging metals in the mountains, page 40

Job Profile

Making moments last forever, page 45

Biz Side

Get equipment deductions, page 57

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November / December 2011 Vol. 52, No. 6

Downtown Banner Elk with Banner Elk Cafe across the street. The cafe is home of Blue Mountain Metalworks custom bike rack. Story, page 40

Biz Side

NOMMA Network

Sell value, not price............................ 52

Kelly’s Ironworks hosts Gulf Coast NOMMA Network.................. 10

In addition to watching demos and having roundtable discussions, attendees toured Steel Fabricators of Monroe, LA.

Moving forward in a changing economy.............. 15

Shop Talk Drawing large Acanthus leaves..................................... 25

The Acanthus leaf has been a design motif for centuries. This article explains how to draw these simply in 11 steps. By Robert Walsh Shop Talk The Zen of designing metalwork........................ 30

Creativity often doesn’t come naturally. For many, it is a learned skill. This six-step process will help you develop original design ideas. By Robert Walsh

The aluminum advantage.............. 34

As a replacement for original cast iron, architects often accept the more forgiving and easy-to-weld aluminum. By Jon McGraw Welcoming new technology.

NOMMA’s 54th Annual Convention and Trade Show will be Feb. 29–March 3 in Orlando. Here’s the complete program and registration form. Sign up now!

Forging metals in the mountains ................................. 40

Working in high elevations, especially in winter, make for challenging installs and special opportunities. Just ask NOMMA Gold award winner Dirk Brown at Blue Mountain Metalworks. By Peter Hildebrandt

Making moments last forever.... 45

Losing his own son’s smile inspired Jack Klahm to help MOMS create a peaceful sanctuary for other families missing smiles.. By Lisa Bakewell

Exec. Director’s Letter.... 8

Find the hidden takeaways.

Biz Side 8 Ways to close a sale....................... 54

Being useful to your customer. Understand what’s in it for them, and how and why you can meet their needs, not your needs. By William J. Lynott Biz Side

Member Talk

Job Profile

Shop Talk

President’s Letter........... 6

METALfab 2012

Your customers want salespeople who can check their ego at the door and listen to their needs. By Michael Stone

Get equipment deductions while you can........................................... 57

Soon-to-expire tax incentives make badly-needed equipment more affordable than ever. By Mark E. Battersby What’s Hot! Business............................................... 66 People.................................................... 66 Events.................................................... 67 Literature............................................. 68 New Products..................................... 69 Nationwide suppliers..................... 63 New members.................................... 65

NEF Chair Letter............ 12

Metal Moment............... 74

Craftpersons learn bronze forging techniques.

Humbling creations.

About the cover Spaceship Earth is the visual and thematic centerpiece of Epcot at Walt Disney World Resort.

See the METALfab 2012 Convention Guide, page 15. Photo credit: Visit Orlando. November / December 2011 n Fabricator


NOMMA O fficers President James Minter, Jr. Imagine Ironworks Brookhaven, MS

President-Elect Will Keeler Keeler Iron Works Memphis, TN

Vice President/ Treasurer J. R. Molina Big D Metalworks Dallas, TX

Immediate Past President Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

F abricator D i rectors Todd Kinnikin Eureka Forge Pacific, MO

Ray Michael R & F Metals Inc. Clinton, MD

Mark Koenke Germantown Iron & Steel Corp. Jackson, WI

Mark O’Malley O’Malley Welding & Fabricating Inc. Yorkville, IL

Keith Majka Majka Railing Co. Inc. Paterson, NJ

Greg Terrill Division 5 Metalworks Kalamazoo, MI

S u ppli er D i rectors Wayne Haas Cleveland Steel Tool Co. Cleveland, OH

Rick Ralston Feeney Inc. Eugene, OR

Gina Pietrocola D.J.A. Imports Ltd. Bronx, NY

NOMMA E ducation F ou n dation O fficers Chair Roger Carlsen Ephraim Forge Inc. Frankfort, IL Vice Chair Christopher Maitner Christopher Metal Fabricating Grand Rapids, MI Treasurer Mike Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

T rustees Heidi Bischmann The Wagner Companies Milwaukee, WI Carl Grainger Grainger Metal Works Nichols, SC Will Keeler Keeler Iron Works Memphis, TN Lynn Parquette Mueller Orn. Iron Works Inc. Elk Grove Village, IL

NOMMA C hapters Florida Chapter Britt Gordy, President Liberty Aluminum Co. Fort Myers, FL (239) 369-3000

Northeast Chapter Keith Majka, President Majka Railing Co. Inc. Paterson, NJ (973) 247-7603

Gulf Coast Chapter Scott Colson, President Iron Innovations Inc. Clinton, MS (866) 924-0640

Upper Midwest Chapter Mark Koenke, President Germantown Iron & Steel Corp. Richfield, WI (262) 677-2530

NOMMA S taff Executive Director, Editor J. Todd Daniel Managing Editor Robin Sherman Sales Director Sherry Theien


Meetings & Exposition Manager; NEF Executive Director Martha Pennington Member Care & Operations Manager Liz Johnson


Dedicated to the success of our members and industry.

President’s Letter

Welcoming new technology If your shop is like mine, your

time, is easier to use, and imwelding machines vary in age. proves the appearance and You might have some that are quality of a job definitely has relatively new, and you probmy attention. ably have some that are 10 or 20 I know hard-liners scoff at years old. modern technology. They want The two best things about to do things the old-fashioned those older machines is that way. That’s fine because there is James Minter, Jr., room for those who can forgethey still work and that they Imagine were paid for a long time ago. weld their work. Those who can Ironworks, is We have an aluminum MIG president work metal as it was done in welder that was old in 1980. It’s of NOMMA. days of old can perhaps charge balky at times, but it still works a premium on their work. for us regularly. Before a recent NOMMA Board What would Mozart do? of Directors meeting in Atlanta, our But do you really think that AmaExecutive Director Todd Daniel had deus Mozart, if he were alive today, early-arriving directors tour the facilwould be composing on a harpsiity of a major player in the welding chord? Would Charles Dickens write industry. They make a variety of equipout his novels in longhand? ment and supplies for welding, from I think that both of them would welding machines and exhaust systems use the most modern instruments and to welding wire and welding flux. methods they could find to produce It was a cool experience because their art. And as for those old-fashthey also demonstrated their equipioned artistic blacksmiths, they are ment in a state-of-the-art training probably using a gas forge and a power area. hammer, not a coal forge with a hammer and an anvil. No more spattering noise My 19-year-old son will tell you In the training area, it was handsthat I am slow to embrace new techon time with some definite “big boy nology. But I am changing my ways. toys.” Now the sound that I am used My first President’s Letter was writto hearing from a MIG welder, that ten out in longhand; this one has been familiar “bacon-and-eggs” spattering written entirely on a computer. sound, is not heard from the welding Enough people have shown me machines that are built today. all the neat applications available on Today’s welding machines are an iPhones that I am seriously considerexample of science overtaking art. A ing “needing” one. welder can set up the machine based And this Facebook and LinkedIn on the material to be welded, its thicksocial media stuff? Maybe I need to ness, and how much weld is required. pay attention and learn more about it Then the welding machine is ready to during a NOMMA webinar. quietly lay down the optimum weld. As for our 30-something-year-old aluminum MIG welding machine, I Got my attention think it’s time to put it out to pasture Some say that a welder using one and replace it with something more efof these new MIG welding machines ficient and reliable. can lay down a bead that looks as good as a TIG weld and is easily cleaned up. This means less time is spent on a welding project. Anything that saves Fabricator n November / December 2011

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Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA). O&MM Fabricator / NOMMA 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles! Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: 888-516-8585. E-mail: Advertise Reach 8,000 fabricators For information, call Sherry Theien, Ph: 815-282-6000. Email: Ads are due on the first Friday of the month preceding the cover date. Send ads to: Fabricator at address above. E-mail ads to: (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: Membership Join NOMMA! In addition to the magazine, enjoy more benefits as a NOMMA member. To join, call 888-516-8585, ext. 101. For a list of benefits, see membership ad in this issue. Exhibit in METALfab Exhibit at METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at 888-516-8585, ext. 104, or Subscriptions Subscription questions? Call 888-516-8585. Send subscription address changes to: Fabricator Subscriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: (888) 5168585, or E-mail: 1-year: U.S., Canada, Mexico — $30 2-year: U.S., Canada, Mexico — $50 1-year: all other countries — $44 2-year: all other countries — $78 Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOMMA members, a year’s subscription is a part of membership dues. NOMMA Buyer’s Guide Published each December as a separate issue. Deadline for all advertising materials is October 31. Contact Sherry Theien at 815-282-6000 or 2011 Editorial Advisory Council Doug Bracken.......... Wiemann Metalcraft Nancy Hayden......... Tesko Enterprises Tom McDonough.... Master Metal Services Rob Rolves................ Foreman Fabricators Inc. Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA. © 2011 National Ornamental & Miscellaneous Metals Association 8


How to reach us

Executive Director’s Letter

Find the hidden takeaways In this new economy, I keep

But the best NOMMA hearing the expression “gaining Power is when you make proan edge.” The idea is to have one fessional contacts around the more “plus” in your arsenal to country. Need a job installed in win a job. Can you make youranother state? Call a NOMMA self a little more efficient to get brother or sister. your bids down a few dollars? Is And as your colleagues get there one more “value added” to know you, they’ll send you Todd Daniel service you can offer your cus- is executive referrals, or they may even tomer? Do you have just a little director of subcontract a project to you, or NOMMA. more knowledge than someone the two of you may even partelse? Can you woo your client ner on a job. Now, this is true with your superior product POWER. knowledge? Do you know how to negotiate and upsell to get Get plugged in the best price for your product? The more you are involved with I know just the place where you can your trade association, the more obtain the “edge.” It’s called your indusopportunities you have for gaining a try trade association. Imagine tapping “takeaway.” We are all extremely busy, into a 53-year-old bastion of informabut if you can get away for a Saturday tion with an online knowledgebase, chapter meeting or a NEF class, you 14 hours of FREE online education are again exposing yourself to new videos, education conferences, and people, and new ideas! opportunities for networking. If you And best of all, if you attend the take advantage of the printed and elecnational conference you are in the tronic resources of NOMMA, I assure heart of a thriving organism full of you that you will obtain your edge. ideas and energy. METALfab is like the But better yet, the real power comes core of the sun — bright and powerful. from what you learn at education sessions and workshops. My personal experience And then there is the most powI am a member of a society of assoerful information source of all — ciation executives. When meetings are your hundreds of fellow professionheld, I often think of a dozen reasons als around the country. You can tap why I can’t attend, but I make myself into this resource through our annual go. I always wonder when and where METALfab conference, NEF events, I will find my next “takeaway.” Will it and electronically via our ListServ, be from a keynote speaker, a class prewebinars, and phone conferences. senter, or the person sitting next me? All combined, I call this Sometimes I will share, and sometimes “NOMMA Power,” and it’s this power I will receive, but always I will gain. that gives you the edge. At my last meeting, I didn’t think I was going to get my “takeaway,” but A ‘NOMMA Power’ charge then, surprise, I ran into a colleague The mystery of NOMMA Power in the parking lot and we had a great is that you never know when you’ll conversation. Those takeaways are receive it. A METALfab class instruchiding at every corner, and I guarantor could give you a single tip that tee that if you join and get involved in could save you hundreds of dollars. Or, NOMMA, you will find them. a vendor at the trade show might show you one new product or give you a single idea that could save thousands. Fabricator n November / December 2011

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The NOMMA Network

Kelly’s Ironworks hosts Gulf Coast NOMMA Network

The Gulf Coast NOMMA Network Group enjoyed a nice turnout and participated in shop tours, demos, and roundtable discussions.

The Gulf Coast NOMMA Network enjoyed a packed day during their Oct. 8 meeting in Monroe, LA. Serving as host shop for the day was Kelly’s Ironworks LLC. An “early bird” dinner was held the evening before at the Cypress Inn, which is a seafood restaurant that sits on an authentic Louisiana bayou. On Saturday, the day of fun began with a business meeting at which NOMMA Executive Director Todd Daniel updated attendees about METALfab 2012 and technical affairs. Afterward, a roundtable discussion included the first demo of the day on measuring techniques. Several attendees shared their measuring device or told about their favorite methods. Of interest was a discussion of measuring apps for the iPhone. Attendees then made the short drive to Steel Fabricators of Monroe, which is a full service structural steel plant that is one of the largest steel firms in Louisiana. Leading the tour was company President John Hunter who led attendees through the various buildings in the complex. Once back at the host shop, everyone was treated to a delicious barbe10

Above, attendees admire a piece of equipment at the host shop, Kelly’s Ironworks. They also discussed measuring applications for the iPhone. Left, outgoing president Scott Colson, Iron Innovations Inc., Clinton, MS, right, passes the gavel to incoming president Charles Perez, B&O Machine Welding, Brookhaven, MS.

Fabricator n November / December 2011

cue lunch, which was followed by the traditional buck-in-abucket raffle. For the afternoon session, Scott Colson, Iron Innovations Inc., Clinton, MS, led a presentation on driveway gate installations and educated everyone on the F-2200 and UL325 safety standards. For the grand finale, the family members at Kelly led everyone on a shop tour. Kelly’s Ironworks, a 61-year-old business, recently moved into a spacious facility that provides huge areas for fabricating, storage, and painting, as well as room for a large showroom in the front and offices. The company is a traditional iron shop that produces a full range of ornamental products, including rails, gates, fences, balcony rails, and spiral stairs.

Tour of Lincoln Electric Co.

members must pay for their own expenses. In addition, occasional phone conferences, online votes, and other functions will require your attention. The Kozik and Blum awards

The Awards Committee is seeking nominations for two of NOMMA’s most prestigious awards: n Frank A. Kozik VolunBefore the NOMMA fall board meeting in Atlanta, GA, in mid teer Service Award. This is October, eight board members traveled to the nearby Lincoln an award for outstanding Electric Co. southeast distribution center. volunteerism, given to a During the visit, attendees were treated to a classroom NOMMA member who conpresentation and a tour of the warehouse. Afterward, the board tinually serves both the tried equipment in the company’s education center. In addition to seeing all the latest products, host Russ Farrar industry and others year talked about new technologies in manufacturing that will likely after year. Its namesake, trickle down into fabrication shops. For example, he discussed Frank A. Kozik, set a great wavelengths that can be customized for particular welding jobs. example by continuing to A “thank you” goes to Russ and Dervon Douglas for their contribute to NOMMA even exceptional hospitality. after he was off the Board. n Julius Blum Award. Letter to the editor Editor’s Note: The measuring presentaThis award is for any person or tion was recorded and we plan to Cash flow vs. profits organization that upload it to the member’s area. makes outstanding Editor, contributions to I worked in business all my the industry. The Call For NOMMA life and although I understood it, award is bestowed directors and award I struggled to explain the conto those who have nominees cept of cashflow to managers and used their gifts and employees. The NOMMA Nominating Committee talents to promote Tim Berry (September/October The Julius Blum is seeking nominations for the 2012– and advance the 2011 Fabricator, pages 60–61) did it Award 2013 slate, both for fabricator and industry. better than I have heretofore heard supplier directors. Please send nominations for both it explained and in three concise Serving on the NOMMA Board of directors and awards by Dec. 15 to: sections. Please pass on my thanks Directors is a great way to “give back” Bruce Boyler to him. to your industry. Boyler’s Ornamental Iron Inc. Greg Frank Are you interested in running for 800-798-4766 Southeastern Metal Crafts a director position or know someone 563-355-1721 fax Villa Rica, GA who would make an excellent date? If so, please submit the following information: n Nominee’s name and company (you may nominate yourself). n Short description of qualifications, achievements, etc. As a NOMMA director, you will have a role in developing the association’s ongoing roadmap and ensuring that we stay on course. An important requirement to serving on the Board is that you must be able to attend Board meetings, which are held three times a year. Board November / December 2011 n Fabricator



NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

Craftpersons learn bronze forging techniques Workshop attendees take home forged bracelets or letter openers By Roger Carlsen NEF Chair Ephraim Forge Inc.

Roger Carlsen, far left in photo, instructs the class on various layout techniques.

Attendees at the NOMMA Educa-

tion Foundation Fall Continuing Education Class had a great opportunity to explore bronze/ silicon bronze forging, welding with a MIG welder, texturing, and finishing. I conducted the hands-on workshop, and everyone left with either a hand forged letter opener or bracelet using the lessons they learned in the class. A special thank you to goes to: n Lynn Parquette, Mueller Ornamental Iron/Elite Architectural Metal Supply LLC, Elk Grove Village, IL, for hosting the event; n Atlas Metals Sales, Denver, CO, for supplying the bronze; and n Brad Humel with CS Unitec, Norwalk, CT, for his finishing demonstration.

Students practice the techniques they learned around a layout table.

Instructor Roger Carlsen, admires a student’s work during NEF bronze workshop.

Donate items for NEF Live and Silent Auctions

Now’s the time to start thinking about your tax deductible item to donate for the NEF Auctions held in conjunction with the Theme Dinner (Thursday, March 1, 2012) at METALfab 2012 in Orlando, FL. Items may range from metal sculptures and garden gates to gift certificates, use of condo on the beach, airline tickets, specialized services,

A sampling of items sold in last year’s silent auction.

Each student went home with either a hand forged letter opener or bracelet.

or even custom one-of-a kind items specially made for the bidder. We also invite you to attend the auction and bid on these treasures. All proceeds support the operation of the NOMMA Education Foundation and its programs. For an auction donation form, go to and click on “Foundation,” or contact Liz Johnson at or 888-5168585 x 101.


For more information on donating to the NOMMA Education Foundation Contact Martha Pennington, 888-516-8585 x 104, 12

Fabricator n November / December 2011

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METALfab 2012

National Ornamental & Miscellaneous Metals Association

54th Annual Convention, Trade Show Moving forward in a Changing Economy

3, Orlando, FL February 29–March the Entrance to Universal Orlando DoubleTree Hotel by Hilton at

METALfab 2012

Your best face-to-face educational value An invitation from James Minter Imagine Iron Works NOMMA President 2010–2011

An invitation from Roger Carlsen Ephraim Forge Inc. NOMMA Education Foundation Chair 2009–2011

I want to extend a very important invitation to you to attend METALfab 2012 in Orlando, FL, Feb. 29–Mar. 3, 2012. I believe that you will go home with numerous ideas that will help you “Move Forward in a Changing Economy.” We may call ourselves metalworkers, but we are really just small business owners who work with metal. If we don’t get the business part right, all the skill in the world as metalworkers won’t help us stay in business. When I attended Michael Stone’s class at METALfab 2003, I had my eyes opened to a whole new way of operating a business. Instead of just opening the doors and hoping for the best, Michael preaches a pro-active and systematic approach to running a business. I used to think that if I concentrated on the revenue numbers, the profit would take care of itself. Wrong! It’s the bottom number on the income statement that is most important, that profit number that determines whether a business succeeds or fails. It was Michael Stone who helped drive that point home for me. I am a big fan of Michel Stone, and I really look forward to having him with us at METALfab 2012 in Orlando.

I know that people who have used the ListServ think it is the best tool that NOMMA offers. Many of you have said that the information you get from the ListServ is worth the cost of an annual membership in NOMMA. However, I think that an even better tool is the annual METALfab convention. I would like to invite all of my fellow NOMMA members to the METALfab 2012 in Orlando, FL, where you can see one of the true values of NOMMA membership. Extensive planning will bring people together to help us through some of the toughest economic times in recent memory. The education program includes our own talented members, but presentations from James Feldman and Michael Stone will help us with change, thinking outside the box, marketing, cashflow, advertising, sales, and contracts. And Saturday’s demonstration tent will offer exciting and informative demonstrations. Yes, all of the above are valuable, but I think the most valuable aspect of METALfab is interacting with our fellow members and future members. NOMMA members are so very willing to share ideas, innovations, problems, solutions, insights, and encouragement, which can best be experienced through direct, face-to-face interaction. And so I look forward to seeing old friends and making new ones at METALfab 2012.

Ferris wheel photo on previous page © admiralkm, 16

Fabricator n November / December 2011

METALfab 2012

Get business skills, talk shop, see demos Two dynamic speakers will provide you with thought-provoking ideas to help you move your business forward in a difficult economy.

We will review: n A marketing plan for NOMMA members. n Setting a budget for advertising your company. Where to advertise and when. n How to avoid “me-to” advertising. n Building a referral network for leads. n

Keynote James Feldman, a certified facilitator and an internationally recognized professional motivator, trainer, speaker, and author from Chicago (http://, will present the keynote speech and a follow-up education session on Wednesday, Feb. 29. Feldman will show you how to go from business as usual to business as un-usual to leverage change and thrive during turbulent times. His talk, entitled Shift Happens, will identify short-term opportunities that will create long-term benefits. Feldman concentrates on overcoming entrenched cultures and habits, introducing innovative thinking and risk-taking to develop solutions that will have you lead the field by increasing value rather than reducing price. You will learn how to accelerate change for success with a deliberate, disciplined methodology that delivers dramatic results.

Business Sessions Shift Happens Wednesday, Feb. 29 After Feldman’s keynote speech, continue the Shift Happens discussion in a two-hour class. It includes how to use his 3DThinking process to go beyond mere creativity to innovative problem solving, at every level, to impact your bottom line. We have been taught to think “outside the box”. Yet, the problem is “inside the box”. For that reason many companies have developed solutions to the wrong problems. Feldman has developed a three-dimensional process that will keep you from being “boxed out” by typical analytical thinking. Through 3DThinking, you and your company will learn processes to develop new areas of innovation. With 3DThinking, Jim uses “try-angles” to “look inside the box” for 1) the depth of your knowlNovember / December 2011 n Fabricator

James Feldman, a well known trainer, speaker, and author, is delivering the keynote address.

Michael Stone, one of our most popular past presenters, is giving five classes at METALfab 2012.

edge, 2) the distance to the solution, and 3) the determination to carry out your intentions. 3DThinking can increase your performance, enhance productivity, and boost profits. Mark Up and Profit Michael Stone, Construction Programs & Results, Camas, WA (www., will present five classes at METALfab 2012 on Thursday, Mar. 1, and Friday Mar. 2. Stone, whose theme is Mark Up and Profit, is a coach and consultant for construction-related small businesses. His expertise lies in business management solutions and computer software programs for the residential construction industry. Thursday, Mar. 1, and Friday Mar. 2 Markup, Margins and Cash Flow. How to set and use markup or margins to reach your sales price and how to prevent cash flow problems within a construction related company. You will discover: n How to avoid the financial pitfalls that most contractors fall into. n How to set the correct markup or gross margin for your company. n The three main causes of cash flow problems. Marketing, Advertising, and Getting Your Phone to Ring. How to build a marketing campaign that will attract customers willing to pay a fair price for your work.

Sales — Back to the Future. How to deal effectively with unrealistic customer expectations on job pricing. We will cover: n The cause of price objections. n The customer’s three biggest fears. n How to ask the four basic questions and find good customers. n How to become the contractor of choice. Contracts, Additional Work Orders, and Punch Lists. Documents written to prevent expensive customer problems. You’ll learn about: n Basic but necessary contract language. The payment and signature page. n How to write change-work orders n and get paid on time. n Stopping the never-ending “punch list.” n Contract language to corral in the problem customer. What Your Family Needs to Know About Your Business. Setting up your company so it is not a problem to your family: n Where is everything. n Who you do business with. n Employees, their jobs, and what the agreement is. n Who your business partners are. n How to pass things along. NOMMA Roundtable Discuss NOMMA and industryrelated questions with NOMMA Board Members and/or industry experts. We’ll break into small groups to discuss issues facing our industry and share solutions and resources. The full group will reconvene to share ideas from the breakout sessions. 17

METALfab 2012 The In’s and Out’s of Welding Rick Harrell, Lincoln Electric Overview of work safety practices, maintenance of equipment, review of welding symbols and corresponding welds, cutting torch operations, stick welding procedures, procedures to clean and evaluate welds, and cutting and preparing metal plates. Plus: Health hazards associated with welding and cutting operations.

Technique Sessions

Technology Sessions Leveraging Technology: IT Investments that Pay Off Lee Flynn, R&F Metals Inc. With all the technology available today, how do you choose the right business applications for your company? Explore hardware and software solutions that increase productivity and add to the bottom line. Discussion to include latest trends in information technology, such as VoIP, Saas, virtualization, and cloud computing. Video Shop Tours James Minter, Imagine Ironworks A visual tour of several NOMMA shops, including Lightning Forge in Utah. See how each shop manages workflow and pick up ideas for your own facility. This extremely popular session has become a METALfab tradition. Understanding OSHA Fall Protection Pat Stark, USF Safety FL Consultation Covers OSHA requirements for construction fall protection, especially residential fall protection requirements. Discussion to examine the dynamics of falling and the importance of following OSHA requirements when people are working 6 feet or higher on construction sites.

What Installation Method Is Best for My Job? Mark O’Malley, O’Malley Welding and Fabricating Tips, tools, and tricks that Mark has discovered by trial and error, and picked up from other NOMMA members and classes. Areas to be covered: One man field measuring, bringing field info to the shop, fixturing and shop layout, material handling, installation, and combining tools to be more useful (e.g. CAD drawings and a plotter can produce a full-sized drawing that allows you to eliminate shop layout so the time spent on shop drawings covers your shop layout, saves time, and improves accuracy). Choosing the Correct Finishing Procedure for your Project Mel Drendle and Frank Grimm, Creative Iron Solutions Compare and contrast “good, better, and best” finishing options for your project. Explore the reasons to use a combination of surface preparation/pre-treatments, coatings, primers, and topcoats. Discussion to include lacquers, enamels, waterbornes, sprays, urethanes, epoxies, powder coatings, and baked enamels. Back to Basics: Measuring Straight and Curved Railings Keith Majka, Majka Railing Company Learn how to take field measurements in a “universal language” so it is easier to communicate with other companies. Presentation includes measuring curved railings without the use of templates. Fasteners: Which is the Correct One for your Installation? Examination of the types of anchors, anchor applications, and load types to meet your job requirements. Plus: New products and installation techniques to save time and money on every jobsite. Building a Non-Ferrous Railing Tony Martinez, Big D Metalwork Learn basic techniques and tips about when to use mechanical methods versus traditional weld-


Fabricator n November / December 2011

METALfab 2012 ed methods for building a non-ferrous railing. Scroll Class Roger Carlsen, Ephraim Forge Inc. This class covers the design of scrolls, fixture and jigging to produce the scrolls, and the production of scrolls.

Demonstrations Foldforming Phil Hermance & Art Ballard, Art’s Work Unlimited Inc. The techniques of CharlesLewton Brain, who got his initial training in Germany and later earned a master of arts from SUNY New Paltz. In the 1980s, he invented a way of working with metal that exploits its inherent behaviors and developed the science and art of foldforming to its current high standard. A demonstration will show the numerous forms that can be developed quickly and easily with copper using the foldforming technique. The Down and Dirty Part of “Finishing” Tony Martinez, Big D Metalworks Learn basic techniques for polishing Stainless Steel — from a #4 Satin Finish to a #8 Bright Finish, plus aluminum and bronze polishing and antiquing, cleaning and hiding welds, and when to use mechanical methods rather than welded ones.

Induction Heater for the Small Shops Roger Carlsen, Ephraim Forge Inc. Induction heating is a method of providing fast, consistent heat for manufacturing applications which involve bonding or changing the properties of metals or other electrically-conductive materials. Learn how this technology can be applicable and affordable in a small shop. Part II of this class will be a demonstration of the capabilities and versatility of the machine from heating to brazing, melting, and even forge welding. Scroll Demo Roger Carlsen, Ephraim Forge Inc. The demonstration portion of the scroll class will focus on the forging of scroll ends from the simple to the complex. Plus: transitioning of multiple scrolls.

Hotel Information

n Room rate cut-off. Jan. 30, 2012 at 5:00 pm, Eastern, or when the block sells out, whichever happens first. n All reservations must be guaranteed and accompanied by a first-night room deposit or guaranteed with a major credit card. n Reservations have a 72-hour cancellation policy. n All early departures are subject to an early departure penalty of one night room and tax. n All attendees must identify themselves as a member of the Group to receive the group rate and to have their reservations credited to the Group block.

The Doubletree, a Hilton hotel at the entrance of Universal Orlando, is the METALfab 2012 host hotel. Rates Single thru Quad...........................$129 Additional person................$10 each Jr. Suites (1 bdrm)........................ $299 1 Bedroom Exec. Suite................. $399 2 Bedroom Exec. Suite.................$499 Penthouse Suite........................... $600 Two ways to make your reservation 1) Go to and use the link to make your reservation 2) Call 1-800-327-2110 and identify yourself as a member of the Group “MET.” Photo courtsey of The Doubletree. November / December 2011 n Fabricator

Please make your reservation early so that you can be part of the great networking opportunities found outside the day’s activities in the host hotel. 19

METALfab 2012 Special Events

This is NEF’s way of saying thank you for your support of the Foundation and its programs.

First Time Attendee Orientation Wednesday, Feb. 29, 10:30 am–11:30 am This is a great opportunity for first time attendees to meet the leadership of NOMMA/NEF and to learn more about the events at METALfab 2012. This event is not just for first time attendees — anyone who has questions and would like an event overview may attend. “Shift Happens” Jim Feldman, Keynote, Annual Membership Business Meeting Wednesday, Feb. 29, 1:00 pm–2:30 pm Education Session follows: 2:45 pm–4:30 pm This is the membership’s opportunity to attend the annual membership business meeting where officers and directors are elected, committee reports are submitted, and special recognitions are given. A special treat for attendees: Keynote speaker Jim Feldman,, will speak. Theme Dinner: Dress up as your favorite character Thursday, Mar. 1, 6:30 pm to 10:30 pm If you could work at an Orlando theme park for a day, what character would you be? Dress like your favorite Disney, Universal, or Pixar character and have a wonderful evening with great music and food. Plus: Participate in the NEF silent and live Auctions held during this event. Bring your wallet so you can take home some wonderful items donated to benefit the NOMMA Education Foundation (NEF). Partner in Education Reception Friday, Mar. 2, 6:45 pm–7:45 pm Join the NOMMA Education Foundation (NEF) Board of Trustees for food and fun.

Top Job Competition Wednesday, Feb. 29, 4:30 pm–7:30 pm Thursday, Mar. 1, 10:00 am–4:00 pm NOMMA member companies are given the opportunity to cast their ballot. Please remember, one vote per company, so plan who will vote for your company. Voting takes place on the trade show floor during show hours on Wednesday, Feb. 29, 4:30–7:30 pm and Thursday, Mar. 1, 10:00 am–4:00 pm. NEF Live/Silent Auctions Thursday, Mar. 1, 6:30 pm–10:30 pm Without a doubt, the NOMMA Education Foundation Auction has become one of the most anticipated events held each year at the METALfab Convention. With the generous help of our donors, bidders, and auction volunteers, last year’s auction raised more than $12,000 to support the educational and research work of the NEF! All proceeds help the Foundation provide quality education opportunities for the ornamental and miscellaneous metals industry through continuing education programs, video productions, and educational publications, as well as supporting special projects important to the industry. Top Job Jamboree Friday, Mar. 2, 5:00 pm–6:30 pm Once voting ends, the action continues during the Top Job Jamboree, where images are flashed on a screen and entrants describe their superb work. On Saturday, the excitement is in the air as the contest winners are announced during the Awards Banquet. The grand finale is the presentation of the Mitch Heitler Award for Excellence, which is given to one gold award winner who shows exceptional craftsmanship.

Annual Awards Banquet

Saturday, Mar. 3, 7:00 pm–10:30 pm During this special time, the new officers and directors are installed, special recognition is given to outstanding NOMMA members, and the Ernest Wiemann Top Job Awards winners are announced. The grand finale of the evening is the awarding of the Mitch Heitler Award for Excellence, which is the top award chosen from the gold-level award winners. This is a must-attend event and a great opportunity to see some of the best jobs of the year! 20

Fabricator n November / December 2011

METALfab 2012 Spouse Program For METALfab 2012, the spouse registration package has a lot of wonderful additions, and is available to attendees who register before February 20, 2012. The spouse registration includes: Trade Show opening reception, classes, tour of Winter Park, theme dinner, NOMMA Education Foundation Auction, Partners in Education reception, Trade Show admission, and awards banquet. Classes, Thursday, Mar. 1, 11:30 am–3:45 pm n Posies Presto! Sometimes we need to put a flower arrangement together unexpectedly. Watch as Chris Holt (Master Gardener with Phipps Conservatory and Botanical Gardens, Pittsburgh, PA, and fabricator at Steel Welding, Freedom, PA) show you how to make simple but effective arrangements from your garden or with a few flowers from a local grocery. You’ll get some excellent gardening tips, too. n Bunko Tournament. Bunko is a game of chance, not skill, played with dice in a tournament format. Now for the real description: Bunko is great fun with dice and an easy way to make friends at METALfab 2012. Make plans to play! n Acrylic Class for Beginners. Have fun discovering your hidden talents with this fun, easy acrylic painting class taught by Mississippi artist Maxine Minter. n Dance Class. Join Sally Nibblelink for a beginner’s class in a jazzy version of a historic dance called the Shim Sham. It is a favorite of Lindy Hoppers & Tap dancers. It will be easy to learn and lots of fun. Wear comfortable shoes for this class.

Winter Park tour, Friday, Mar. 2, 9:00 am–4:00 pm Join the other spouse registrants for a tour of Winter Park, FL, originally developed (1887) for wealthy Northerners as a summer retreat. You will be taken to the Park Avenue shopping district where the Southern charm that lured the elite society can still be seen. Picturesque shops, boutiques, cafes, brick-lined streets, and the towering trees of Central Park make Park Avenue the place to be. Start your tour with a relaxing, 45-minute the Scenic Boat Ride (pontoon boat) gliding through canals and tree lined lakes. View beautiful homes nestled along beautiful lakes and observe nature. Then enjoy the Charles Tiffany Chapel at the The Hosmer Morse Museum of Charles Hosmer Morse American Art, which houses the Museum of American Art. world’s most comprehensive Photo credit: Visit Orlando. collection works of Louis Comfort Tiffany (1848–1933) works, including Tiffany jewelry, pottery, paintings, art glass, leaded-glass windows, lamps, and the chapel interior he designed for the 1893 World’s Columbian Exposition in Chicago. And you’ll enjoy a wonderful lunch at the Park Plaza Gardens.

Program schedule

November / December 2011 n Fabricator


METALfab 2012 METALfab 2012 Trade Show Why should you participate in the METALfab 2012 Trade Show? n Touch,

explore and realistically evaluate products. n See firsthand the latest trends and technologies. n Learn about hundreds of the best products and resources available. n Discover new products through demos and one-on-one with industry experts. n Meet some of the best people in the world and form new working relationships. Show Hours Wednesday, Feb.29, 4:30 pm–7:30 pm (Reception 6:30 pm–7:30 pm) Thursday, Mar. 1, 10:00 am–4:00 pm Friday, Mar. 2, 9:00 am–12:00 pm METALfab 2012 is proud of our sponsors Platinum Sponsor ■ Industrial Coverage Corp. ■ The Wagner Companies Gold Sponsor ■ Lawler Foundry Corp. Silver Sponsor ■ Julius Blum & Co. Inc. ■ Colorado Waterjet Co. ■ EPi — Electrochemical Products Inc. METALfab is the annual convention and trade show for the ornamental and miscellaneous metals association sponsored in partnership by the National Ornamental & Miscellaneous Metals Association and the NOMMA Education Foundation. For more information on METALfab, NOMMA and NEF, go to or scan the adjacent QR code, at right. We look forward to seeing you in Orlando, FL, Feb. 29–Mar. 3, 2012. You may register using the form on page 23 of this magazine or go to 22

Fabricator n November / December 2011

METALfab 2012 Attendee Registration Form

DoubleTree by Hilton Hotel at the Entrance to Universal Orlando, February 29–March 3, 2012 The special prices, discounts for multiple registrants* from the same company, and the spouse registration fees below expire Feb. 20, 2012. After Feb. 20, 2012, a late fee of $100 will be added to all registrations.

Step 1: Registration Options Choose your registration type and enter the names for badges. ❑ Full Conference Package Members only n n

Keynote Speaker & Opening Session Education Program (includes Saturday demos)

Trade Show (includes Opening Reception) n Theme Dinner n

NEF Auction Awards Banquet n Demos on show floor n n

Price 1 full registration: $395


2 full same company: $375 each*


3 full same company: $365 each*


4 or more full same company: $350 each*


Example: 3 people from same company: $365 x 3 = $1095 ❑ Education & Trade Show Package Members only $295 n Education Program (includes Saturday demos)

❑ Spouse/Guest Package Members only $299

n Keynote & Opening Session n


Trade Show (includes Opening Reception)

n Demos - show floor

Name_____________________________________________________ Name_____________________________________________________


Trade Show/Opening Reception (Wed., Feb. 29, 2012)


Theme Dinner/NEF Auction (Thu., Mar. 1, 2012)


Special Classes for Spouses (Thu., Mar. 1, 2012)


Spouse Tour — Winter Park Tour (Fri., Mar. 2, 2012)


Awards Banquet (Sat., Mar. 3, 2012)

Above registration is not available after Feb. 20, 2012.







❑ $595 Include a NOMMA membership so that we can obtain the great member pricing. Non-Member Registration Reduced pricing for multiple attendees is not available with non-member registration. ❑ Full Package $595


❑ Education and Trade Show $495


❑ Spouse/Guest Package $499


Individual Tickets Tickets will not be available for purchase after Feb. 20, 2012 ❑ Welcome Reception (Wednesday, Feb. 29, 2012) $30 ❑ Theme Dinner (Thursday, Mar. 1, 2012) $105



❑ Spouse Tour — Winter Park Tour (Friday, Mar. 2, 2012) $105


❑ Awards Banquet (Saturday, Mar. 3, 2012) $75


Step 2: Payment Method Select payment type Check (payable to NOMMA in U.S. dollars on U.S. bank) Check #_____________ ❑ American Express

❑ MasterCard


❑ Discover

Card #___________________________________________________________ Exp. Date___________________________________________________ Name on card____________________________________________________ Card CVV___________________________________________________ Signature_____________________________________________________________________________________________________________________ November / December 2011 n Fabricator


METALfab 2012 ✂

Step 3: Tell Us About Yourself Be sure and enter name(s) beside appropriate registrations that you selected on other side of this form.

Please check the appropriate ribbon labels below for inclusion in your registration packet.

Company _______________________________________________________________________

❑ New Member

❑ Committee Member

❑ First Time Attendee

❑ Chapter President

❑ NW Supplier Member

❑ Chapter Member

❑ Fabricator Member

❑ NEF Contributor

Address_________________________________________________________________________ City_____________________________________________________________________________

State ___________ Zip_____________________ Country_________________________________ ❑ Regional Supplier Email___________________________________________________________________________ Phone___________________________________ Fax____________________________________ On-site Emergency Contact Number_________________________________________________

❑ Member

❑ Gold Member — 20+ Years

❑ Local Supplier

❑ Past President

❑ Member


❑ Affiliate Member

❑ NEF Trustee ❑ Officer

Person to contact in case of emergency______________________________________________ ❑ Committee Chair

❑ Officer

❑ Speaker

Step 4: Attendee Profile Tell us about your business This portion of the registration must be completed for processing. ❑ Check here if you are not involved in the business. If you are not involved in the business this is all of the information needed. Thank you. List three (3) products you hope to purchase from contacts at METALfab 2012: _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 1) Primary type of business

2) Annual gross sales

3) Your role in purchasing

4) Job description

❑ Fabricator

❑ Below $1 million

❑ Final Say

❑ Owner

❑ General Supplier

❑ $1–$2.5 million

❑ Recommend

❑ Manager/Foreman

❑ Contractor

❑ $2.5–$5 million

❑ Specify

❑ Other____________________

❑ Over $5 million

❑ Other____________ ___________________

Additional Information Registration Registrants can pick up their packets at the METALfab/NOMMA registration desk in the hotel convention center registration area. Attendees on the trade show floor must be 14 years of age or older for insurance purposes. Children under the age of 14 will not be allowed on the trade show floor. Cancellations If received in writing prior to Feb. 23, 2012, we will be happy to refund your registration fee, less a 15% administrative fee. Understandably fees cannot be refunded for registrations cancelled after that date. Registrations are nontransferable without the written permission from NOMMA. Cameras Photography and videotaping are not permitted on the show floor, education sessions, or Top Job Gallery. Emergency Contact We would like to have contact name and phone number in case of an emergency. This person would be contacted only in the event that you were unable to contact them yourself.

Return to

Questions? Call 888-516-8585, extension 101, or email

805 South Glynn St., Ste. 127, # 311

For updated information go to

Fayetteville, GA 30214

Online Registration is available on the NOMMA website

Fax: 888-279-7994

Multiple registrations from the same company cannot be processed online.


Multiple registrations should be processed by fax 888-279-7994 or email


Fabricator n November / December 2011

METALfab 2012

Shop Talk

Large Acanthus Leaves The Acanthus leaf has been a design motif for centuries. This article explains how to draw these simply in 11 steps.

By “Uncle Bob” Walsh If you can draw a letter “C” and an “S,”

you can draw Acanthus leaf patterns. Once the pattern is made, with a band saw, forge, and a few basic tools, making the leaf does not require a high skill level. Acanthus leaves can be complex and require a high skill level to produce, but that is not what we will describe here. Is what I am going to walk you through how a French masterpiece is made? No. Is what we will do here applicable for interior work? That is questionable and depends on the application. What we will address here is the use of thicker metal and hot forming. a process typically for large work, gates, and railings. Smaller Acanthus leaves used on interior work, lighting, and furniture typically would be thinner metal that can be more finely detailed with hammers and stakes. Thinner metal is worked cold. Is the Acanthus leaf process we are going to work through here visually effective and applicable on a fine home November / December 2011 n Fabricator

that is not a European castle? Yes. Will what we are going to walk through here be cost effective? Yes. These leaves may add a couple days to a large gate and railing job, but they may also land you the job when competing with other shops. Receiving or losing a job makes them highly cost effective. Finally, can we make these leaves in any size or shape so we have complete design freedom? Absolutely. If you’re still with me, let’s go to work. This article comes with assignments that you can do on your kitchen table. I hope you find them useful. Get yourself an 8.5 x 11 sheet of paper, pencil, eraser, and cup of good coffee. I like a little cream in my coffee. Step Now on your sheet of paper, draw 1 a loose “S” as in illustration #1.

Keep it loose. This will be the main vain or spine of your Acanthus leaf.

Step On the main spine of your Acan2 thus leaf, add four “C” curves that

will represent the center of your petals

For your information



About the author Robert Walsh (Uncle Bob) has been a fabricator/artist/blacksmith for 30 years. For 10 years, his shop was in downtown Minneapolis. After the invention of the fax machine (allowing an easy interchange of sketches), he moved to semi-rural Wisconsin where he set up a cottage industry with fellow shop owners that has been chugging along for 20 years. Their ironwork can be found throughout the upper Midwest. CO NTAC T

R. Walsh Gate & Railing 306 Lake St. Pepin, WI 54759 715-442-3102


(for lack of a better term). Now, you will like this, these lines do not have to be on the money at all. They just give us a reference point to work from. Feeling uncomfortable? Don’t. Remember, if you can draw a “C” and an “S” you have the skills. Hang in there and feel reassured that nobody is looking! Tell your wife or husband the kitchen is off limits for 20 minutes. Step Now, we start alternating “C” 3 curves and “S” curves, which

are what these stylized Acanthus leaves are all about. Above all your curved petal lines, draw “C” curves (crescents), which will represent the tops of each individual petal. These “C” curves go from a little out from the center (spine line) to the tip of the center of the petal line previously drawn (illustration #3). Step Now, it starts to become fun. 4 From the connecting point of

the two lines previously drawn, add an “S” curve down towards the top of the petal below it. Actually, on the tail


of your “S” curve is the beginning of a following “S” curve. Think of this line as a little train of “S” curves. If you are starting to scratch your head again, don’t. We will not use any of these lines at all. All of the above are just construction reference lines to work from. Remember, no one is looking so you won’t have to apologize for what you are drawing, or reading instructions that refer to “a little train”! Soon it will be time to refill your coffee cup. Step On the top, again, add a “C” 5 curve on the convex side of

the main spine and an “S” curve (and a half) on the concave side. Ornamental iron Acanthus leaves are highly stylized leaves and are mechanical in construction. Ornamental iron Acanthus leaves are not botanical reproductions. Step Now we finish out the bot6 tom. What I am after here by

broadening the base, is something

Fabricator n November / December 2011

reminiscent of what a twig might look like when broken off a branch — a wider area where the connection to the branch was. This is simply a suggestive form. We now have all our reference lines, so if needed, it is OK to get that second cup of coffee. Acanthus leaves are all about ornamentation. With that in mind, let’s make our leaf more ornamental. To do this, we will divide up the petals, which will add more action on the outer perimeter. Dividing the petals allows us to stamp in more veins from the outer edges of the petals (perimeter) in towards the central spine. We want to load this leaf up with visual activity.

leaves, I don’t let them protrude out at all. We’re after an overall form that has “grace.” If these little toes stick out too far, the overall form suffers. The “grace” (fluidity) of the leaf gets lost. Look at the photograph; notice how the small lobes are kept within the flow of the leaf on two of the three examples. Grace is the goal. Step Divide up the 9 tip as we have

just done to the side petals.

Step Erase and adjust 10 all lines as need-

ed to make everything look proportional. Don’t worry about your paper becoming sloppy. Step Round off the 11 pointed tips on

the five large primary lobes. This makes the leaf inviting and not prickly looking. Although in early repoussé styles, the prickly look is appropriate. The leaves we are making here are Acanthus leaves that are mechanized and highly developed in style. We are not copying nature. We are making decorative forms. I leave the secondary, small lobes somewhat pointy as I feel the contrast looks good.

Step Let’s start on the tops of the 7 petals. This is easy. Re-draw

(tighten up) a “C” curve to represent the top of a petal so now it comes in lower by about 40% when compared with where it was originally was located. Next, flip up a short curved line past the original “C” curve. Now add a new “C” curve above where the original “C” curve was. The old “C” curve is now obsolete. Repeat this process on the tops of all the petals. The petals grow a little in size (fill out) during this process.

A little tip about drawing

Step It is now “S” curve time. From 8 the outside end of a petal, re-

place the original “S” curve with a smaller (tighter) “S” curve to again add more lobes to the petal. Like before, add a short curved line from the new shorter “S” curve to/or a little past the old “S” curve. Now, add a new “S” curve down as needed. Repeat this sequence on the rest of the petals. November / December 2011 n Fabricator

I like to make the new lower lobes we are now creating not stick out much farther (if at all) than the original pattern (keeping the silhouette pretty, much the same as it originally was). The examples here protrude out a little. More often than not, on large

One way to make a nice looking drawing, is do as we have been doing with a pencil. Once all your pencil line work is where you want it to be, then with an ink pen (I often use a common ball point pen) go over your messy pencil construction drawing. Let the ink dry well and then with a soft eraser (good erasers are soft and do not ruin your paper) erase all the pencil construction lines. Apply a little whiteout as needed. Photocopy this to further 27

clean up your paper and walla! stylized leaves, not botanical To make the finished drawing reproductions. accompanying this article, I made Finally, there are many ways a huge construction mess with to embellish your leaves. A few a pencil on a large sheet of paare in figure #12. per (17 x 22). Then, lay a sheet of For large Acanthus leaves, tracing paper over the mess and we will use the layout method traced the refined lines. above to create Acanthus leaves Once this tracing is where you that will be for your specifwant it, spray with a clear “fixaic projects. Impossible to do tif,” which is basically a mat finish through a magazine? Not at all. clear lacquer. The fixatif seals the The process is easy and I suspect graphite (lead lines) so they do you will find it fun. not smudge. Plus, Acanthus leaves put tri-state-quarter 12/19/07 Then getpage.qxd the drawing copied 9:44 AM Page 1 visual body (mass) into your in full size or reduced to a smaller wrought iron (linear) projects, fax-size or scan-able email size. which generally makes them Whiteout can be applied to any look better. mistakes you may have missed. Let’s talk about how far to exPractice tend our lines from the perimOnce you get comfortable eter to the center spine. From my drawing these leaves, they beexperience, I run the lines all the come simple and mechanical. way down, if I am illustrating. If you run the line all the way to the Remember, there is no magic here. When drawing, incomplete lines center on the actual metal (especially The leaves are stylized Acanthus bother the viewer. When actually with a raised vein), often you run into leaves, not botanical reproductions. making the leaves, however, I never tooling problems at the intersection. The leaves are based on alternating - 45-3454-ACF-121807-V2 run these side lines to the central vein. AD PROOF Remember, these are mechanical “C” curves and “S” curves.

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November / December 2011 n Fabricator


Shop Talk

The Zen of designing metalwork

By “Uncle Bob” Walsh Creativity. You may already have it. Creativity might be a

talent for some, but for the rest of us, thinking creatively is often a developed skill. Process and products fundamentals

n All original products are outgrowths of ideas (concepts). n A process is the vehicle used to turn your idea (concept) into a reality. n An original product needs both, the concept (idea) and the process to make it a reality. As metal artist Marcia McEachron puts it, “imagination plus skill equals creativity”. With this said, if a concept is at the root of all original products, let’s focus on concepts, which can be artistic ventures or solutions to problems you may have (“necessity is the mother of invention”), or anything in-between. People get creative ideas in different ways. I can only speak from my own experience, but I suspect the process below might be universal. Typically, a concept (idea) is easily conceived, or you think about the challenge for a day or two and up pops the solution, and you just do it. This is great. However, if for some reason you need to come up with a concept and you draw a blank, try the following.

The Zen of the creative process



Creativity often doesn’t come naturally. For many, it is a learned skill. This 6-step process will help you develop original design ideas.

What I am after when pursuing an idea is a state of mind that is totally relaxed. And I mean totally relaxed with regard to the concept being pursued. Have you ever noticed how your ideas or problem/solutions often come when you least expect them? For instance, you stress over developing a solution or concept and then drop the subject in frustration. Then at 3 a.m., you go to the bathroom and wham, up pops the solution, and it’s a great solution because it came from your imagination and was not hampered by specifics from your intellect. Or, after putting the challenge out of your mind because of frustration, you are driving your car down the highway not thinking about anything and again, wham, you’ve got the solution and it’s great. This may be where the old Chinese proverb comes into play “You have to give to get.” In this case, you have to give up the pressure on your intellect so your imagination can surface and give you the solution. The farther away you are from searching for your solution, the more relaxed your mind will be for the search, and the more it can provide you with a solution. As explained in Betty Edwards book, Drawing on the Right Side of The Brain, you need both your intellect (knowledge and reasoning skills) and your imagination Fabricator n November / December 2011

(ability to create ideas) to make original things happen. According to the book, a person needs to shut down their intellect, which is more developed in an adult’s mind and is dominant, so your less developed imagination can surface and provide you with the solution. Once your imagination has provided you with the concept, crank up your reasoning skills, refine the idea, and make it happen. How can a person develop this left brain/right brain process so that it is a usable skill? How can a person learn to shut off their intellect so they can create with their imagination? No problem, but it does take a little self-discipline and practice. Here goes:

1 Identify the challenge

First, a person must identify what their challenge is. What are you trying to achieve? For the sake of this article,

I am going to use two examples. Example 1: Create an artful design concept for a decorative hand-forged front security door for a home. Example 2: Develop a design proposal for a courtyard sculpture.

2 Visualize the size

OK, now we know what the concept needs to be, let’s establish the size and shape for the locations. The door, we know, will be rectangular, and the sculpture will be a size based on the proposed location. Then on a piece of paper, use a ruler to draw the proportions of your proposed object.

3 Refine the challenge

Next, establish some of the appropriate elements you’d like to use in this project. In the case of the front door, if classical, what elements fit this style of architecture? Sketch these elements

next to your proportion layout. Also, are grids or patterns appropriate? What is the mentality behind this style of home? How can you build on the mentality to take it further? In the case of your sculpture, what would you like to do? Do you have elements you like to work with? Is there appropriate subject matter? Give yourself some design guidelines. Now look at your sheet of paper and develop your element guidelines. These guidelines are not carved in stone; they just provide a point of reference from which to start. Put some thought and research into the guidelines and make your list of options extensive. Building this list gets you into the spirit of the project and your many design choices will now start to appear. The more energy you put into your homework, the easier the conceptualizing process becomes.

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4 Apply some pressure


What we need to do now is cook. Put your sketch in a prominent location where you will see it often. In cooking terms, I like to think that we put all the ingredients into a pot on the stove. Now push the pot to the back burner. Let it simmer. How long does it need to simmer? More specifically, create a due date. Without a due date, it will probably never happen.

5 Let it happen


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The simmering process on the stove and the deadline keep your project cooking in your head, but not in a pressure cooker. By keeping a little pressure on (leaving your sketch out where it keeps reminding you of what you are doing and by when), you are waiting for your intellect to relax and get out of the way so your imagination can provide you with the concept. If you are sincere and commit to your due date, when you are driving your car, going for a walk or doing some other mindless task, watch, and I suspect your imagination will serve you well.

6 Record the gift

Lastly, when the idea pops into your head, sketch it ASAP. If you don’t make a simple note or sketch, you might not remember the idea later. Many imaginary concepts are fleeting. The process may seem unreliable, but after working with clients over the course of my career, somehow it has almost always pulled me through. Thus, the keys to success are: a) Doing your homework well b) Taking care of yourself so you can think clearly and c) Committing to the process. Failures on my end have usually been because I dropped the ball in one or more of the three categories above. As the Chinese proverb goes, “You have to give to get.” In this situation, give up your dominant intelligence and let your imagination provide you with a concept to work with. Once your imagination has given you the concept, put the pedal to the metal with your intelligence (knowledge and reasoning) refined, develop the project and make it happen!

For your information For complete information on all stock components, visit or email

P.O. Box 816 Carlstadt, N.J. 07072-0816 800.526.6293 201.438.4600 fax 201.438.6003



Julius Blum & Co. Inc. is the nation’s largest supplier of architectural metal products.

About the author Robert Walsh (Uncle Bob) has been a fabricator/ artist/blacksmith for 30 years. For 10 years, his shop was in downtown Minneapolis. After the invention of the fax machine (allowing an easy interchange of sketches), he moved to semi-rural Wisconsin where he set up a cottage industry with fellow shop owners that has been chugging along for 20 years. Their ironwork can be found throughout the upper Midwest. CO NTAC T

R. Walsh Gate & Railing 306 Lake St. Pepin, WI 54759 715-442-3102

Fabricator n November / December 2011

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The aluminum advantage Fig. 1: Right, the cast iron piece, aluminum match plate, and the duplicated aluminum casting.


As a replacement for original cast iron, architects often accept the more forgiving and easyto-weld aluminum.

By Jon McGraw Alloy Casting Co. Inc. Replacement castings are often required

Fig. 2: Above, these designs were fabricated “loose� to save on the cost of permanent tooling.

Fig. 3: Right, the pattern board used for the large corner bracket.


during renovation and restoration projects. Sometimes, these duplicate castings must be reproduced from old pieces taken from the job site. But, if no samples are available, drawings, old photos, or faded newspaper clippings might contain enough information for successful duplication. On a small scale, these projects may involve a homeowner who needs two or three pieces to repair a fence, or, on a larger scale, a government agency that is restoring a turn-of-the-century post office. Because of the age of the castings being reproduced, almost all of the old designs have been originally made in cast iron. However, fabricators and architects readily accept aluminum replacements for these cast iron pieces. Aluminum is more forgivFabricator n November / December 2011

ing than cast iron. It is easily drilled and fabricated, lighter in weight, rust free, and simple to weld. Moreover, if the project involves attaching aluminum castings to a steel frame, a steel clip, bolt, or stud can be placed in the aluminum casting during forming. This steel insert can then be welded to the steel framing. Restoration projects usually have some economic constraints. If the job calls for only a few replacement castings, the tooling charges may be excessive for a small number of individual pieces. On these projects, our foundry reproduces directly from the older casting sample by forming a mold around the “loose” sample. By producing the new casting in a “loose” manner, tooling expense is unnecessary, but the higher labor cost of this approach makes for a higher per piece cost. We always try to achieve the lowest overall cost for each casting. Working with John Graney, John Graney Metal Design, Sheffield, MA, a recent project of ours entailed castings originally made in the mid-1800s. Four different cast iron designs had been fabricated as a veranda onto a house originally built in 1806. The project meant making aluminum replacement pieces based on the cast iron originals. A piece of the running oak top frieze was cleaned and used as a pattern sample to fabricate an aluminum match plate. The match plate captured all the many curves and see-through openings. The cast iron piece, the aluminum match plate, and the perfectly matched aluminum casting are shown in (Fig. 1). Two other designs, the “X” oak and the scroll frieze required only 20 pieces each. Because the piece count was low, these two designs were fabricated “loose” to save the expense of permanent tooling (Fig. 2). Steel welding pins (3/8 inch diameter) were cast into the two designs so they could be welded to the steel framework. The last casting in the project, the large corner bracket, was reconfigured and set up on a wooden pattern board (Fig. 3). The different approaches used on each of the four designs achieved the lowest cost for each casting. November / December 2011 n Fabricator

Four different cast iron designs had been fabricated as a veranda onto a house originally built in 1806. The project meant making aluminum replacement pieces based on the cast iron originals.





Fig. 4: The original, Civil War-era gazebo. Fig. 5: The reproduced aluminum casting.

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We helped Frances Flaherty, Flaherty Iron Works, Alexandria, VA, on another mid-1800s historical project: the restoration of an eight-sided gazebo, circa 1860, at a Civil War Naval Hospital in the Richmond, VA, area. Alloy Casting made the aluminum castings from the original cast iron pieces. After casting, the surface was distressed to make them look old like those (See Fig. 4) of the original gazebo and (Fig. 5) for the reproduced aluminum castings. The Civil War foundry craftsmen were skillful because we had much difficulty duplicating their workmanship with the small and tight hole structure of the original castings. Because there were only two big and two small castings needed, we did not make tooling but, again, ran the castings “loose.” Duplicating hand rail posts

Restoration of existing facilities where no samples are available can be achieved from a sketch or drawing. Alloy Casting, in conjunction with Pete Shaw, Shaw Mfg., Hilton Head, SC, and H. M. Kern Construction, Greensboro, NC, fabricated matching hand rails for the Almance County Fabricator n November / December 2011

For your information


About the author Jon McGraw of Alloy Casting Co. Inc. regularly writes for Fabricator. His first article appeared in 1987.

courthouse in Graham, NC. We duplicated aluminum rail posts from the original 1914 wood post. The project included an exterior handicap ramp with illuminated grip rail and a new interior stair well. The tooling for the post was fabricated from the sketches. (Fig. 6). The next photo (Fig. 7) shows the post pattern made from the sketches. All posts were cast in corrosion resistant marine grade aluminum.

About the company Alloy Castings, a NOMMA member, is a longtime industry supplier. The firm specializes in custom aluminum castings, both for decorative and functional needs. CO NTAC T

Fig. 6: Top left, the sketch for the courthouse post. Fig. 7: Top right, the post pattern made from sketches. Fig. 8: Bottom, a two-piece handrail bracket.

Alloy Casting Co. Inc. 3900 South Peachtree Rd. Mesquite, TX 75180-2724 972-286-2368 972-557-4727 fax

Creating hand rail brackets

Sometimes an historical restoration is small and out of sight. Bruce Rienks, Evans Metal Products, Elkhart, IN, had a project at the old Palace Theater, South Bend, IN, originally built in 1921. Alloy Casting’s role was duplicating seven sets of a unique two-piece handrail bracket (Fig. 8). These pieces were easily fabricated “loose”. The diversity of projects that fall under the concept of renovation and historical restoration is endless. Any project, from homes, theaters, gazebos, bridges, and roof cresting to even antique cars can be completed with aluminum castings. Final castings can also be reproduced in brass, bronze, or stainless steel. Each project, big or small, provides an economic opportunity for the fabricator and the foundry. The key items to consider for reproduction are the quality of the sample item submitted as a pattern and the economic trade-off between the number of castings required and the amount of tooling investment needed to achieve the lowest overall cost. November / December 2011 n Fabricator





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Member Talk

Custom bikes on wall of the front area of Blue Mountain Metalworks.

For your information


What you’ll learn n The advantages, opportunities, and challenges of taking over a business from a longtime NOMMA member. n How artistic metalwork and functional projects can be part of your business and incorporated on a single project. n The benefits and challenges of running a metal shop in a high elevation and winter sport resort area. n How everyone being boss can help everyone to function even better in a small shop operation. n The importance of “good faith” jobs to endear your business operations with the local community. n How one small metalwork operation in a resort area managed to keep going during rough economic times. CO NTAC T

Dirk Brown Blue Mountain Metalworks 567 Main Street Banner Elk, NC, 28604-8974 828-898-8582 828-898-8570 fax About the author Peter Hildebrandt is a long-time senior writer for Fabricator. He is a general interest writer with a specialty in company profiles.


Forging metals in the mountains n

Working in high elevations, especially in winter, make for challening installs and special opportunities. Just ask NOMMA Gold award winner Dirk Brown at Blue Mountain Metalworks.

By Peter Hildebrandt If you’re going to do the kind of work you love

doing, you might as well do it in a scenic place where there’s plenty of skiing, hiking, bicycling, horseback riding, golfing, rafting, and fishing. Surrounded by some of the highest mountains east of the Rockies, the Town of Banner Elk, NC, is home to a lively arts and crafts cultural scene that includes Blue Mountain Metalworks and its owner, Dirk Brown. Originally from Oxford, OH, Brown attended nearby Appalachia State University in Boone, NC, while also working in an area bike shop. After graduating with a bach-

*Ed Powell has another company now, Marric, LLC in Jacksonville, FL. Though this new firm is not involved in steel fabrication, Powell, through Marric, remains a NOMMA member. Powell reviews AMP (Architectural Metal Products) manuals. These brochures are guidelines for the industry. He also is an active volunteer in the Jacksonville area and is glad the metal shop he started up in Banner Elk is continuing with its metalworking mission. Fabricator n November / December 2011

Combination railing and bench system, above, in front yard of Boone’s Jones Community Center.

thing from small copper items to medium-sized structural, including beds, rails, chairs, barstools, cabinet hardware, wine racks, coat racks, metal trees, and plenty of toy-sized bikes, reflecting this recreation area’s passion for mountain biking. They also do restoration jobs, such as lamp refinishing and rebuilding. These days, gates and railings make up about 40% of the business. The rest is composed of fire screens, furniture, window boxes, and custom specialty bike racks. Fire screens are a big item Continued on page 43

Hook-style bicycle rack, left, in front of the Mellow Mushroom restaurant, in Boone, NC.

elor’s degree in art, marketing, and production from ASU in 1993, Brown stayed in the area he liked so well and pursued his interest in sculpture and metal work. He worked for Charleston Forge, a Boone, NC, wrought iron furniture manufacturer, and still does some work for them. In 2001, Brown saw a tiny ad from Ed Powell (see footnote, page 40), past president of NOMMA. Brown ended up sitting with Powell for two or three hours and found they got along very well. Brown worked at Charleston Forge during the day and then would come over to Banner Elk in the evenings to work for Powell, who had retired from his shop in Jacksonville, FL, and moved to Banner Elk to set up a little shop called Powell’s of Banner Elk. After several months of working evenings, Powell established a sizeable workload and brought in Brown full time. “It was a true education every day to work with Ed,” says Brown. Powell, being versed in all aspects of the ornamental and architectural metalworking field, taught not only the most effective ways of fabricating rails or November / December 2011 n Fabricator

gates, but would also use the old-style techniques he learned in his early education and experience in the field. In 2005, a driveway gate designed by Brown won NOMMA’s gold medal for outstanding craftsmanship. In 2006, Brown purchased the business from Powell, incorporated it, and named it Blue Mountain Metalworks. Blue Mountain creates every-

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Dirk Brown has his “Pet Projects List.” In the wintertime, or when business is slow, he will call folks who are on his list. These are his friends who have requested an item “when things are slow.” These are fun projects to fill in the gaps. Blue Mountain is not really a structural welding shop, but they do help with utility equipment welding. “More and more folks are figuring out we can do work ‘while they’re waiting’ in the winter,” says Brown. “We get a lot of weird repairs, such as those involving mower decks, motorcycle kickstands, or even snowplow repair. That is usually a good faith job to get people to come back, and they’ll take a business card before they leave. Word of mouth can bring in work.” Brown feels that finding the right niche items helps keep a steady cash flow. One of their objectives is finding out what people are actually interested in and will buy, such as their decorative bicycles. Additionally, winter is a good time to focus on one’s online presence. Blue Mountain posts recent projects on its Facebook Fan Page to stay connected. They’re also launching an online store on their newly designed website. “We are always looking for opportunities. In the great words of a friend of mine who is was a mentor to me in the furniture world, ‘opportunities abound.’ They’re out there; sometimes you just have to dig them up.”

Fabricator n November / December 2011

in the fall and winter, the time of year that brings snow and skiers to the area. But Brown says that despite the relatively high area elevations and snowy weather, he had just one day last winter that he couldn’t go from his home in Boone to Banner Elk. Power outages from ice storms are much more of an issue, bringing work to a halt and causing a loss of work time. When the power is out, Brown finds that’s the time to keep the heat on by turning on the forge and working on craft items or catching up on other forging needs. “Spring and fall are probably our biggest times of year, generally, and this year’s been pretty consistent — a relief from the last couple of years,” says Brown. But winter is a chance to catch up on numerous downtown possibilities (see sidebar, page 42).

Award winner. In 2005, a driveway gate designed by Dirk Brown won NOMMA’s gold medal for outstanding craftsmanship.

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Unusual installations

Brown enters the shop with nearly $700 worth of rolled copper to form planters within the intricate planter frames already laid out on the workbenches. As he sets the copper down, he brings up an ever-present challenge in the business, the fickle costs of needed metals. Copper, as it turns out, had just had a cost increase, which could have lead to complications regarding the agreed-upon price of a job, but he’d already built some wiggle-room into the quote he’d given this client. “Every job is a challenge. Also, for any jobs over $500, I make sure to get something in writing and a final number that takes into account material prices increasing.” The downturn in the economy in the last couple of years brought a lot of remodels instead of new construction; so, like many others, Brown is not getting the margins he’d like to have. “But our steel suppliers say if you’ve survived through the last couple of years, you’ll probably be all right,” Brown says. “We’re ready to make a little more profit and get rolling again, but happy to have the work we have now.” Their current job is in Dutch Creek Falls, a double install. They must weld a gate, put three window boxes up on November / December 2011 n Fabricator

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a second story all while dealing started working in the summer. with an 80-foot waterfall pourBrown says that despite only ing down nearby, a challenge having two employees, one of not many fabricators have. Five his challenges is directing and people will be working on this delegating. install. “But one thing I’ve learned “No two jobs are alike,” adds over the years is that I might be Brown. “Each job has its own the boss, but if what I’m doing challenge. We did one job on is wrong, or someone sees a beta ski country condo on Sugar ter method they can speak up Mountain that required a 100and be my boss; we watch each ton crane to bring the railing other’s backs.” in through the backside of the Because the shop has a fairly condo because there was no way large work area for only three Otter Vasgard and Josh Voncanon heating segment of railing to get it up the stairwell. We had before bending the section. workers, shop work flow is not a crane lift it over the building much of a problem. Their Big and bring it in the back door. Then Blue Hammer is near the back of we had to build cranes to bring that the shop, and layout and fabrication rail up through the 16 inches of pastables are closer to the front office sage between the roofline and the area for easy access. balcony.” A garage door on the side near On another job, Blue Mountain the back accesses an open area and area arborists resolved a probwhere chalk markups can be done lem that the Jones House Comon the floor. The angle of bendmunity Center in Boone had with ing for a railing job is worked out dying maple trees. The trees were and marked, the metal heated red struggling because people were hot before being set in the Hossfeld walking on their roots. The curvbender, and all three men in the ing fence and bench system, dubbed Dirk Brown, Otter and Josh bending a heated shop work to bend the railing into the “fench,” that Brown’s shop con- railing piece. place when needed. structed protects those roots and prohas two employees, Josh Voncanon Storage in the shop is ample. For vides places for visitors to sit. In the and Otter Vasgard. materials, the shop does use some reend, it saved the trees from trampled Josh was going back to school and cycled material, visiting the scrap yard root systems. came to the shop looking for part time several times a year to replenish their work six years ago. Now he has finsupply. The where and who ished his degree in Sustainable DevelThe painting and finishing area is a Blue Mountain’s shop space is 3,900 opment and is working full time. new addition to their operations. “This square feet. Previously, six people Otter was looking to expand his area is still in the works,” says Brown. shared that space, but now the shop welding and fabrication skills, and “The way we used to have things set up, grinding took place too close to the painting area, making it tough to always achieve a good finish on items. “With the forge going, all sorts of particulate matter wafted all around the area and even into the finishing area. This is the case unless you have an isolated paint booth. We typically paint in the evening, coming back after the day’s work is done or we will bring someone in to do it.” As for the future, Brown intends to keep going as they have been, despite the effects of the prolonged difficulties with the economy. “We’ll keep shaping metal and keep learning; of course, NOMMA has been a great help with that.”


Fabricator n November / December 2011

Job Profile

Universal symbols of love, eternity, and welcome (the x, o, and infinity symbol) adorn the horizontal top of the MOMS Memorial Park entrance gate.

For your information



Jack Klahm Klahm & Sons Inc. 2151 Northeast Jacksonville Road Ocala, FL 34470 352-622-6565


Losing his own son’s smile inspired Jack Klahm to help MOMS create a peaceful sanctuary for other families missing smiles.

By Lisa Bakewell “God’s work comes to my hands,” says Jack Klahm.

“When you give yourself up, and don’t think that you’re the one in control, it frees up your mind to be able to create pieces. It just opens your mind, and you lose the frustration.” Although Jack Klahm, owner of Klahm & Sons Inc., Ocala, FL, is referring to his artwork in this statement, since the loss of his son, Richard, Jack not only gives up his artwork to a higher power, he has also given himself up to God for healing. Memories live on in the heart — and art

Richard Chandler came into Jack’s life (along with his brothers, Tom and Jon) when Jack married their mom, Becky, in 1985. After leaving the Coast Guard, and until his untimely death in a tragic motorcycle accident on Apr. 16, 2006, Richard worked side-byside with his dad for 15 years. Their father/son bond was a strong one, and Richard’s loss was an unfathomable source of pain for Jack on several levels. Not only had Jack lost a son, he also lost a skilled craftsman and the future successor of the family business. Jack says that his faith in God, and his memories of Richard, kept him from falling into the November / December 2011 n Fabricator

MOMS, Inc. P.O. Box 684 Ocala, FL 34478 352-369-MOMS (6667) holly@ www.memoriesofmissingsmiles. org Memorial items (trees, pavers, memorial rocks, and park benches) are available for specific donation levels. You can also make cash contributions to the nonprofit, which will be used for continued development and maintenance of MOMS Memorial Park. About the Author Lisa Bakewell is a freelance writer, copy editor, and blogger in the Chicago area. Besides writing for Fabricator, Lisa’s work can be seen in ALL YOU, Massage and Bodywork, Pulse, and several other trade magazines. 45

Photo credit, all photos in this article, to Thomas Chandler.

Making moments last forever

hole of remorse or letting his sorrow paralyze him. When remembering Richard’s work, there are two projects that stand out vividly in Jack’s mind. The first project, Jack recalls, is Whitehall. “One of the largest restorations that we’ve done would be the Henry Flagler home, Whitehall, on Palm Beach Island, FL. That side entrance to Flagler’s home was my son’s masterpiece. Richard had to recreate the side entrance from Dedicated to Jack Klahm’s son, Richard, this Via 1901 blueprints because the Paradisus gate won a Silver Award in the Driveway original disappeared. He creat- Gates-Forged category in the 2007 Top Job contest. ed this entry that is 22 feet wide by 17 feet tall — out of aluminum.” design work there. That’s not any inteThe second piece that brings Richrior designer or anybody else.” ard to mind for Jack is his own work Jack won a Silver Award in the at Via Paradisus (Road to Paradise), a Driveway Gates-Forged category in high-end residential community that the 2007 Top Job Contest at METALhad been a renowned race horse facilifab for this one-of-a-kind prestigious ty known as Franks Farm in Ocala, FL. entry gate, and the project remains “I would say that’s the one [gate] one of his favorites, though the memothat is probably the most monumental ries are bittersweet. Richard died durthat I’ve ever done. That’s all of my own ing the fabrication of the Via Paradi-

sus project — where he was in the middle of working on the gate’s arch. The Via Paradisus gate is dedicated to Richard, and his memory lives on, not only through his work, but through the organs he donated (benefitting five people); his children (Richie and Genevieve); and, most recently, through the inspirational gate that Jack created and donated to the MOMS (Memories of Missing Smiles) Memorial Park in Ocala. Shared tragedy is catalyst for healing sanctuary

MOMS Memorial Park was the brainchild of two moms, Holly Sadler and Sharon Lindsey, who lost their sons to tragic car accidents in the same year. Sharon lost her son, Devon, in an accident at Jumbolair Aviation Estates, a fly-in community for airplane owners, in Ocala on Jan. 26, 2008. Five boys were killed speeding down the runway in a BMW M5 and

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Dedication brings surprise visitor

At the gate. From left to right, Jennifer (friend), Jon Chandler (son), Tom Chandler (son), Richie (grandson), Jack, Genevieve (granddaughter), John Travolta, Becky, and Jake (friend) pose in front of the MOMS Memorial Park entrance.

What made this dedication of the gate more special? Jack Kalm said that “in the process of doing [the gate], pictures were posted on the Internet. Because the Travoltas were involved with the project also, John Travolta’s ‘righthand’ person came to the shop and wanted to see [the gate] . . . what was going on with it. He said that John and Kelly [Travolta’s wife] had been watching us here, and they wanted to be able to thank us personally. And so, the assistant said, ‘You can’t tell anybody, but when the dedication date comes up, John will be there.’ ” “I could tell my wife and my two other sons,” Jack went on to say, “but they were sworn to secrecy, because when you have an event like that, you don’t want them to come to see the Travoltas. You want them to come to see the park. “When the ceremony started, Richie and Genevieve were sitting next to me, and John walked up and sat in front . . . and the look on Genevieve’s face . . . ‘Gampa,’ she said, ‘look who’s here!’ “I said, ‘That’s your surprise!’” Jack is so thrilled that his grandchildren have a special, uplifting event attached to the memory of their father, Richard, at MOMS Memorial Park. “I have this one shot of Jon shaking Richie’s hand from the back,” said Jack, “and right next to Jon is Genevieve looking up at John [Travolta], and the look on her face is worth a million bucks!” couldn’t stop before the runway ended with a 30-foot drop. Just a few months later, on May 10, 2008, Holly’s 21-year-old son Kyle also passed away in a car accident in Ocala, though the reason for his accident is unknown. Holly’s original idea was to create a memorial park in the name of Jett Travolta, John Travolta, and Kelly Preston’s son, who died in January 2009. Although the Travolta family resides in Ocala, Holly and Sharon soon realized that it might be best to create the memorial park for the community of Ocala, as a healing sanctuary, rather than draw nationwide attention to it using a celebrity’s namesake. After getting Ocala City Council approval on Dec. 15, 2009, the Memories of Missing Smiles Memorial Park was November / December 2011 n Fabricator

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on its way to becoming a reality. The 5-acre park would be adjacent to Jervy Gant Park, and the plans included two waterfalls, a reflection pond, a butterfly garden, and a 1/3-mile trail. All of the park’s construction and improvements were achieved via in-kind services, contributions of materials and time, and by financial contributions to the MOMS’ nonprofit organization. Several The dedication day of the memorial park: Sept. 24, 2011. organizations, groups, and companies became involved in the ing skills and creativity for an entry project, and John Travolta and Kelly gate to the park. After several unrePreston each offered thousands of dolturned phone messages, Becky was lars from the fundraiser and movgetting frustrated. ie premieres for “From Paris With “Finally,” says Jack, “she left a mesLove” (Travolta) and “The Last Song” sage saying, ‘I don’t think you under(Preston). stand. I want to help donate and make As the park progressed, Becky the entrance for the park.’” Klahm (Jack’s wife), read about the “At that particular point, they MOMS project in the paper and called her back,” Jack chuckled. brought it to Jack’s attention. They agreed that it would be a project they Gift offers gateway to healing would like to be involved in, so Becky Once the Klahms became involved reached out to offer Jack’s metalworkwith the project, Jack took a good look

at the drawing that had been created for the park entrance. “It looked like something you might get at Home Depot,” said Jack. “When I saw what they had, after Becky got me involved with this, I said, ‘No, that’s not going to work.’ When designing an entrance, you need to be able to see something from the distance that draws you in.” As an example, Jack uses Samuel Yellin’s metalwork for the Washington Cathedral, Washington, DC. “There’s a side entrance to the cathedral,” said Jack, “where there’s a set of wooden doors that have strap hinges — and all these rivets on it. The closer you get to the doors; every one of those rivets is different. They have a face or a flower, and it draws you in.” It was Jack’s thought that the same needed to be done when designing the MOMS gate. In his opinion, you needed a gate that would draw you to MOMS Memorial Park from a distance. You needed stature and visual interest. And that’s just what Jack created. Designing and fabricating a welcoming gate

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When designing the gate, Jack knew what size he needed the gate to be, but he also realized he needed to create a memorial entrance that was of a nondenominational nature. To accomplish this task, Jack incorporated several international symbols that are easily recognizable as universal signs of love, welcome, and eternity. “The gate itself is made of aluminum and measures 13 feet wide by 9 feet tall with 24-inch columns [made with cinderblock and synthetic stone] on either side with granite description on the very top of the columns,” said Jack. “Those are precast pineapples — and pineapple is the international sign of welcome.” “At the very top, on the band — just like when you sign your card, you know, love so and so — it has x’s and o’s, and then there’s a horizontal figure eight, which is the eternity sign. So, it’s Fabricator n November / December 2011

November / December 2011 n Fabricator


‘hugs and kisses forever.’” Under the arch, is a banner with raised lettering that reads “MOMS” for “Memories of Missing Smiles.” At either end of the banner, ribbons cascade and twist down. Below the banner, is the logo of MOMS, which is a heart measuring 4-feet wide by 3-feet tall and is made out of 1/8-inch aluminum. Each heart half was hammered in the Pulmax, Jack says, and each half took about an hour-and-a-half. As Jack figures it, “When you have 2100 times a minute times and an hour-and-a-half, that’s about 200,000 hammer dents on each half of the heart!” Once the hammering was done, the halves of the heart were put together in a frame that’s isolated with 2-inch balls, giving the feeling that the heart is “sitting there by itself.” “The framework and everything else is run through my Hebo machines,” says Jack, “so it all has scalloped edges, and the pickets are on a diagonal, so you have a very subtle de-


that it is not about Klahm & Sons. It is about what the park is about —and about this person that I made this for.” Sanctuary, sharing bring peace

A memorial plaque from Richard’s family is attached to the gate

sign. The finish on it is a black/brown with a latex wash for the primary piece of the metal work, the heart is painted with an automotive paint, and down at the very bottom of it, I’ve got a saying there that says, ‘This gate is donated in memory of Richard Allen Chandler II.’ At the bottom of that, it says, ‘Given with love from his family.’ ” “I needed to be able to keep it so

In a way, MOMS Memorial Park is akin to a church without walls, explains Jack. “When you have lost somebody, you can sit on a bench, and maybe somebody else will come by and talk. Maybe this is why you’re here, or maybe the waterfall or the butterfly gardens and the other areas in this park [draw] you here. “The people that I have talked to that have walked in the park say it’s something that is more than a park. It is for therapy and for healing — and people come here for healing. People say that this is the most wonderful place to be able to be because you can’t fall into the hole of remorse or the sorrow. You have to be able to talk about what has happened, and this keeps you from falling into that hole.”

Fabricator n November / December 2011

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Biz Side

Sell value, not price n

Your customers want a company they can trust. And they want salespeople who can check their ego at the door and listen to their needs.

For your information


About the author Michael Stone, whose theme is Mark Up and Profit, is a coach and consultant for constructionrelated small businesses. His expertise lies in business management solutions and computer software programs for the residential construction industry.


costs and overhead expenses, and make a reasonable profit. So how can you make the sale and still charge a fair price? Reasons for choosing a particular contractor

© Scott Maxwell -

Editor’s notes: At the upcoming METALfab Convention in Orlando, FL, Michael Stone will present five classes. Four of them are focused on how to make money in construction — from pricing jobs to marketing, sales, and dealing with clients. See page 17 for more information. By Michael Stone Price is a recurring theme the past few

years with contractors in all the trades saying, “All I hear is that my prices are too high. What can I do or say to get this stopped?” Lowering your price isn’t what you want to do. If you don’t make a profit, your business won’t survive. You need to charge a price for your work that is fair and allows you to cover all your job

The National Association of Home Builders many years ago surveyed homebuilding and remodeling customers in the northeast asking them to rank a laundry list of potential reasons they would choose a contractor. In other words, what did they consider important? The top priority: the individual that the potential client deals with. That was the owner and/or salesperson from the company. The potential client wanted to know they would be dealing with a reputable person who knew their stuff, was honest, and would deliver what the potential client wanted. The second priority: the company itself. The price of the job was seventh on the list. That is correct, #7. So why do you hear that your price is too high? Avoid the giveaways

In almost all cases where I have worked as a sales trainer, price became an issue only after the salesperson made it an issue. Here are some examples of what you may be doing to yourself as you make your sales presentation. Do you advertise anything for free, like free estimates? How about a free consultation or maybe you give something away for free as an incentive? Do you have the word “free” on your vehicle signage or job site signs? Do you have the word on your business cards? If you have “free” anywhere, it is time to get rid of it. The word only atFabricator n November / December 2011

tracts people who are looking for something for nothing. Now, if that is the type of client you are looking for, by all means keep right on with the free stuff. When folks do call you the first time, is your mindset on what they want to do, or is your focus how you can give them the lowest price so you win the bid? Now think about that one. Go over the questions you ask on the phone. Will any of them give potential clients a real indicator of your focus? Your focus should be on one thing only and that is getting an appointment set with a qualified buyer. Too many contractors are in a hurry to ask for the potential client’s budget, which immediately puts the focus on money and puts up a warning flag that your focus is money. Use your qualifying questions for the sales call, when you are eyeball to eyeball with the potential client. Then, body language will tell you as much as their words about where their focus is and where you should direct the conversation. When you’re on the sales call, are you focused first on what they want to do or do you answer their questions on what things cost? Worse, do you start talking about the cost of your service or product, or suggest that one method is cheaper than another? When you are busy telling them how you will do something they want done, is your focus on how to keep the cost down or on what they want to do and why? Price matters. But value matters more. The value of your service has to be equal or greater than the price of your work, but when a potential client first meets you, they don’t have a clue what your value is. If you focus on price, they will think your value is that you are low priced, and that’s where they will focus. However, people who have the money to buy from you and who understand that they must pay for goods and services, also understand there is “no free lunch.” They know that they get what they have paid for. They know they will have to pay to have for the work at some point. They don’t want free. They want good value for their money. November / December 2011 n Fabricator

When a potential client first meets you, they don’t have

a clue what your value is. If you focus on price, they will think your value is that you are low priced, and that’s where they will focus. Be presentable and listen

Most potential clients start out with the unspoken idea of eliminating you to get to the best contractor and price. To overcome this, put your best foot forward from the start so you can be the “contractor of choice”. Your appearance has much to do with the initial impression you make. Are you clean, groomed, and looking nice when you go on a sales call? Don’t go on a sales call straight from a job. Go home first, clean up, and then go. When you step in their house, offer to remove your shoes. Don’t make them ask — offer first. Don’t smoke, drink any alcoholic beverage, or use drugs before or on a sales call. This is a no brainer, but it needs to be said. When you are talking with potential clients, put your ego in your pocket. Listen and ask questions. Yes, you know more than they do about how to build the job, but until you know

exactly what they want to build, you’re just guessing. Want to get their trust? Ask questions and listen to the answers. Keep your opinions to yourself. Summary

Smart contractors let potential clients know right up front that they, not the contractor, set the price for their job. Potential clients set the price through the design of their job and the selections of the materials to be used. And they are in charge of both those factors. Sales isn’t easy, and working with potential clients in today’s economy is even more challenging. But you don’t have to give away your work to make the sale, and if you give away your work you won’t survive. There are construction-related businesses who are thriving in today’s market. It’s not easy. They are putting much more effort into advertising and marketing their businesses, and they’ve learned sales techniques that move the focus off price and onto value. And most important, they’ve done that without lowering their prices. Once upon a time, jobs fell from the sky for many construction-related business owners. It’s not that way anymore, and it might not be that way again for many years. Survival today requires a lot more work and a new set of skills. But it can be done.


Biz Side

8 ways to close a sale n

Being useful to your customer is the key. Understanding what’s in it for them, and how and why you can meet their needs, not your needs, will get you closer to your selling goal.

Photo © chlhii -

By William J. Lynott It has never been a walk in the park even in the best of times. Closing the sale and

getting your prospects to say “yes” these days is an especially difficult challenge. Your competitors are making the sales arena a war zone; most are ready to do whatever it takes to get a signed contract. That’s why you need to mobilize your offense by sharpening your closing skills to a razor’s edge. However, the “take no prisoners” selling style that might have been fine at one time, is not now. Guerilla tactics for closing the sale is not about the cutthroat, hard sell that serves only to alienate sophisticated customers and prospects. Instead, explain your agenda. Tell your prospects exactly what you’re selling, and most importantly, how it can benefit them and their businesses. Here’s how:

1 Sell benefits, not features

Whether you’re working with a contractor or an end user, never lose sight of what your prospects want to know: “What’s in it for me? How will I benefit?” By translating the various features of your workmanship and materials into benefits for the purchaser or end user, you’ll ratchet up your closing ratio by putting human nature on your side. For example, if your prospects are contractors, emphasize how the high quality of your workmanship will protect their reputation with their customers and prospects. If an end user is looking for an iron railing, show how your product will provide a lifetime of safety for the users. In short, always answer the “What’s in it for me?” Question even if that question is never asked.

2 Be a good listener

For most of us, good listening does not come naturally. If you find yourself anxious for the other person to finish talking so that you can get your oar in the water, 54

Fabricator n November / December 2011

you probably need to sharpen your listening skills. Although not easy, once mastered, it’s a skill that will send your closing rate soaring. Train yourself to listen carefully to what your prospects have to say. Nonstop talking on your part will create a hard-sell impression in the mind of your prospects. Instead, encourage your prospects to talk so you can determine your customers’ needs and their reasons for buying. Once these are identified, demonstrate how and why your service or product meets your customers’ needs.

by saying “We’ve built our business on the premise that customer satisfaction is an absolute guarantee.”

5 Look for signals that your prospect is ready to buy

Open-ended questions also give you clues that your prospects are ready Ask open-ended questions to buy. These signals can be both verWhen you’re talking, ask open-endbal and non-verbal. ed questions that require more than a Questions like, “Do you have the simple “yes” or “no.” Open-ended quesmaterials in stock?” or, “What colors tions encourage your prospects to talk. are available?” or “How long have you Thus, the more you will learn about been in business?” are classic examples them, their reason for buying, and of verbal buying signals. CSU-201103-NOMMA Hlf Ad_Layout 2:55 PM Page 1 signals might their objections. You’llFab learn what it 1 1/28/11 Non-verbal buying takes to satisfy their needs. also indicate that it’s time to close the


3 Avoid ‘yes’ or ‘no’ answers to prospects’ questions

Don’t respond to questions from your prospects with a simple yes or no. Whenever possible, answer a prospect’s questions with questions of your own. For example, if a prospect asks how soon you can deliver the project, instead of giving an estimated delivery date, you could say, “When do you need it?” Even if the answer is sooner than you can deliver, the exchange between the two of you will draw the prospect deeper into a buying situation. If the prospect asks whether you guarantee your work, you might reply

For your information


A good book The 11 Laws of Likeability: Relationship Networking . . . Because People Do Business with People They Like By Michelle Tillis Lederman American Management Association 2012 Soft cover $16.95 About the Author Bill Lynott is a long-time business writer for Fabricator. He is the author of three books: Professional Service Management (McGraw-Hill); Power Letters for Service Executives, (Lynco Publications); and Money: How to Make the Most of What You’ve Got (Author’s Choice Press). Bill also has an extensive background in management, consulting, and marketing. Email:

November / December 2011 n Fabricator

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sale. For example, a customer who: n Nods his head with a hint of a smile on his face as you are speaking, n Leans closer to you as the conversation continues, or n Unfolds crossed arms. Among the most positive signals that a prospect is ready to sign on the dotted line are technical questions about the project, complaints about experiences with other vendors, or questions about payment terms. These often indicate that prospects have stopped thinking of objections and are considering more “positive” issues relating to the buying decision.

6 When to ask for the sale

Once you see signals that your prospects are ready to buy, stop selling and directly ask for the sale. Good sales pitches often trail into darkness when the salesperson continues to sell after the buyer sends a strong buying signal — or worse, fails to ask for the sale. There are countless ways to ask for the sale. Among effective closing sentences are such questions as:

n “Will delivery on the 15th work for you?” or n “Which of the two designs do you prefer?” This approach makes the prospect choose between two alternatives, a proven technique for closing the sale. Perhaps the simplest way of asking for the sale is just to ask something like, “Can we agree on this?” Another good way to close is to use as the “authorization close.” When you sense a buying signal, try this: n Ask your customer if she has more questions. n If she says no, put an X on the line of the contract where the customer needs to sign. n Hand her the contract and a pen, and ask her to authorize the sale so you can get the order started right away. Many sales pros feel that the word “authorize” is less threatening than the word “sign,” making it more likely that the customer will oblige. Also, many prospects who feel that they are ready to buy simply can’t pull the trigger. A good closer helps them.

Oftentimes, setting a deadline will move a prospect toward the dotted line. If you honestly feel that the price may go up soon or that you have made a special offer to get the sale, adding a deadline can be effective.

7 People enjoy doing business with people they like

Understanding this characteristic can go a long way toward giving your closing rate a healthy boost. Generally, prospects won’t be motivated by an unlikable salesperson. So, create a comfortable feeling between you and your customers. If you are successful in this or in establishing yourself as your customers’ friend, you will automatically set yourself apart from much of your competition. An way to do this, of course, is to demonstrate your interest in your customers’ needs; concentrate your pitch on serving those needs. Establish a rapport and be more than just a salesperson to the prospect. You can then help your customers’ achieve their goal and be a resource for genuinely useful, how-to, step-by-step information. Showing enthusiasm with facial expressions and your body language helps a lot. A genuine and honest smile can be the most effective tool for creating a friendly atmosphere. Moreover, if you show that you enjoy your work and that your own goal is not to increase your own sales, but is to help your customer be successful, your closing rate will climb.

8 Always be accessible

Let your prospects know that you will be available when they have questions. Create a reputation for customer service. Answer the phone or emails promptly, for example. This will set you apart from other salespersons. Not answering or a delaying an answer to a voice mail or email will send some customers directly to your competition. By following a carefully organized plan in your sales pitch, closing the sale will become a logical and natural part of your selling approach. Forge a mutually helpful relationship with your prospect based on filling the prospect’s needs, and watch your success rate climb. 56

Fabricator n November / December 2011

Biz Side

© Scott Maxwell

Get equipment deductions while you can By Mark E. Battersby

Soon-to-expire tax incentives might be a lifesaver, making badly-needed or replacement equipment and machinery more affordable than ever.

November / December 2011 n Fabricator

Bonus write-off background

Bonus depreciation was originally created in 2002 as a temporary economic incentive by which companies could immediately deduct 30% of the basis of qualifying assets that were placed in service after Sept. 10, 2001 and before Jan. 1, 2005. An increase in the percentage of the deduction in 2003 to 50% expired in 2005. Reintroduced by lawmakers in 2008, bonus depreciation has subsequently been extended three times.

For your information



Thanks to the 100% “bonus” depreciation write-offs created by the Tax Relief, Unemployment Insurance Reauthorization and Job Creation Act of 2010, many ornamental and miscellaneous metalworking businesses are discovering that capital investments in equipment, machinery, and other business assets are more affordable today than ever before. However, the 100% bonus depreciation write-off is available only for qualifying purchases made by metalworking shops and fabricating businesses in 2011. Those metalworking or fabricating businesses that have hesitated or postponed making capital investments because of the recent economic downturn might now consider how the combined use of incentives and the 100% bonus depreciation can substantially reduce the cost of capital investments. Even funding those new equipment purchases is easier — at least for a while.

What You’ll Learn n Investing in equipment, machinery, and other business assets before year-end can reap big tax savings. n 100% “Bonus” depreciation ends, and Section 179, first-year expensing amounts are reduced, after December 31, 2011. n A limited window of opportunity exists to take advantage of fastexpiring financial incentives for equipment acquisitions. n New, improved loan guarantees and reduced or eliminated fees may help spur interest in SBA programs. About the Author For more than 25 years, Mark E. Battersby has written editorial features, columns, white papers, and reports for magazines, journals, newsletters, and websites about news and developments in the tax and financial arenas that impact small businesses. He can be reached at


Although the concept of taking the additional depreciation in the first year is quite simple, changes to the applicable percentage, timeframes during which each is available, and variations related to unique types of assets that qualify have made application of the rules somewhat complex. The definition of property that is eligible for bonus depreciation under the 2010 Tax Relief Act is the same as under prior law, but the percentage and placed-in-service dates have changed. The percentage increased from 50% to 100% for qualifying property placed in service after Sept. 8, 2010, and before Jan. 1, 2012. Those ornamental and miscellaneous metals businesses investing in qualifying assets will be able to fully deduct the cost during the current tax year. This will reduce taxable income and taxes paid, resulting in an increase in cash flow, which can be reinvested in the business.


expensing dollar and investment limits to $500,000 and $2 million, respectively, for 2010 and 2011. The Tax Relief Act included a $125,000 dollar limit and a $500,000 investment limit for tax years beginning in 2012 and expiring after Dec. 31, 2012. Unlike bonus depreciation that applies only to “new� property, a metalworking or fabricating business may immediately deduct as a Section 179 expense, up to $500,000 of both new and used business property placed in service during the tax year. The Section 179 expensing write-off is reduced, dollar-for-dollar, by any property acquisitions in excess of the $2 million investment ceiling, limiting the write-off to smaller businesses. Extending leased property and other write-offs Expensing write-offs

Last fall’s Small Business Jobs Act increased the Section 179, first-year

Before passage of the Tax Relief Act, qualified improvements made to leased property, qualified restaurant property, and qualified improvements

Fabricator n November / December 2011

to retail property that was placed in service before 2010 was included in the 15-year MACRS (Modified Accelerated Cost Recovery System) class for depreciation purposes. In other words, those expenditures could be depreciated over 15 years under the MACRS, standardized depreciation system. The 2010 Tax Relief Act retroactively extended the inclusion of qualified leasehold improvement property, qualified restaurant property, and qualified retail improvement property in the 15-year MACRS class for two years through 2011.

The prime example of a situation bracket and expects to be in a higher crying out for an ornamental and bracket in future years may want to miscellaneous metals business to opt defer depreciation deductions to offset out of 100% bonus depreciation is one future higher-taxed income. where there are about-to-expire net An election to take a reduced bonus operating losses, the value of which depreciation deduction was specificalwould be lost if current-year income ly authorized under prior law, when a were reduced too much by claiming taxpayer could elect 30% — instead of the maximum depreciation allowance. 50% — bonus first-year depreciation. Similarly, a metalworking shop Until recently, however, it appeared Ad_2011:Layout 1 2/7/11 AM that Page or business that currently is, and10:09 in the1only choice for a metalworkthe recent past, has been in a low tax ing business that does not want 100%

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It is not only federal tax write-offs that can help reduce the cost of capital investments. Many metalworking shops and fabricators making capital investments during the 2011 tax year can also benefit from state and local credit and incentive programs. In fact, many states offer a tax credit equal to a percentage of an eligible capital investment made in that state. Eligibility for the credit may depend on the industry or particular use of the underlying asset. For example, Massachusetts, New Jersey, and Oklahoma offer investment tax credits to manufacturing businesses for assets purchased that will be used exclusively in manufacturing activities. Alternatively, Illinois offers businesses predominantly engaged in either manufacturing or retail an investment tax credit for the purchase of all qualified purchases placed in service during the year. Best of all, the assets are not required to be used exclusively for manufacturing or retail activities. Opting out

Although the 2010 Tax Relief Act included the best terms ever for bonus first-year depreciation, namely a 100% write-off of the cost of qualifying property, not all metalworking businesses will find it desirable to use front-load depreciation deductions. While it is possible to elect out of bonus depreciation entirely, at least for now it is less certain that a fabricator can step-down from 100% to 50% bonus depreciation. November / December 2011 n Fabricator

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The SUV in every parking lot writeoff In the past, generous tax breaks for gas-consuming, heavy SUVs often raised the ire of Congress. However, last December’s Tax Relief, Unemployment Insurance Reauthorization and Job Creation Act of 2010 actually made tax breaks for these assets even more generous. Although probably unintended, the limited-time, 100% “bonus” depreciation allowance includes a new, heavy SUV purchased and used for business. That’s right, the entire purchase price can be written-off in the placed-in-service year. A metalworking or fabricating business that buys and places in service a

new heavy SUV — those built on a truck chassis and rated at more than 6,000 pounds gross (loaded) vehicle weight — after Sept. 8, 2010 and before Jan. 1, 2012, and uses 100% for business, may write-off its entire cost in the placed-in-service year. There is no specific rule barring this result for heavy SUVs. Under the 2010 Tax Relief Act, the bonus first-year depreciation percentage is 100% (instead of 50%) for bonus-depreciation-eligible “qualified property placed in service after Sept. 8, 2010 and before January 1, 2012. Qualified property includes property to which Modified Accelerated

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Cost Recovery System (MACRS) depreciation applies with a recovery period of 20 years or less. Autos and light trucks are fiveyear MACRS property and thus qualify for bonus depreciation (assuming business use excess is 50% of total use). Since large SUVs are exempt from the luxury-auto dollar caps because they fall outside of the tax law’s definition of a passenger auto, a metalworking or fabricating business that buys and places in service a new, heavy SUV after Sept. 8, 2010 and before Jan. 1, 2012, and uses it 100% for business, may write-off its entire cost in the placed-in-service year. There is no specific rule barring this result for heavy SUVs. bonus depreciation was to elect out of bonus depreciation entirely. Now, the IRS has decided to follow Congress’ “General Explanation” for the 2010 Tax Relief Act and permit a step-down election from 100% to 50% bonus depreciation. Discretionary incentives

When it comes to a financial helping hand, the best opportunity for metalworking and fabricating shops and businesses investing in capital improvements may be discretionary incentives available at the federal, state, and local level. Many of these incentives require that some level of job creation or, at least job retention criteria be met in addition to capital investment. But there are some notable exceptions. The Federal New Markets Tax Credit, for example, provides a significant financial incentive for qualified investments made in certain eligible census tracts. Delaware and Virginia offer cash grants based on future capital investment made by existing businesses without requiring a commitment to new job creation. The incentives of many local jurisdictions often provide the most significant benefit for capital investment activities. Many municipalities offer Fabricator n November / December 2011

property tax abatement or tax increment financing as tools to encourage capital investment. The property tax-related incentives are typically long-term in duration and provide significant savings for making qualified capital investment.

panies) — private, non-profit corporations that contribute to community economic development. Gone, but one hopes, not forgotten

The Tax Relief, Unemployment Insurance Reauthorization and Job Creation Act of 2010 provided opportunities designed to help businesses reap tax benefits for capital investments and provide funding for doing so. The 2011 tax year may be the optimal time to take advantage of the federal, state, and local tax or financing incentives that encourage capital investments. Under the right capital investment scenario, a savvy business may claim: n 100% federal bonus depreciation, n new Markets Tax Credit, n state investment tax credits, and n municipal property tax abatement on the same capital investment. Or, the business may benefit from the soon-to-expire funding opportunities available today.












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November / December 2011 n Fabricator

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Last fall’s Small Business Jobs Act created the State Small Business Credit Initiative (SSBCI) and funded it with $1.5 billion to strengthen state programs that support lending to small businesses, such as metalworking operations (and small manufacturers). Designed to spur up to $15 billion in lending, January 2011 saw the first wave of awards to the states. Under the SSBCI, participating states may use the federal funds for programs to leverage private lending to help finance small businesses that are creditworthy, but are not getting the loans to expand and create jobs. Last year’s “Jobs” Act included other provisions designed to help small businesses obtain funding. Among that bill’s provisions, several new, but temporary, funding programs, such as the U.S. Small Business Administration’s, amped up extension of its lending guarantee programs and fee reductions. In addition, increases in the maximum loan size for the SBA’s 7(a), 504, and microloan programs will help. The 7(a) and 504 loan program maximums bump from $2 million to $5 million and the microloans increase from $35,000 to $50,000. Loans made under the SBA Express program would temporarily increase from $300,000 to $1 million. Included is a temporary allowance for small business owners to use 504 loans to finance certain mortgages to avoid foreclosure. The SBA’s CDC/504 Loan Program provides long-term, fixed-rate financing to acquire fixed assets (such as real estate and equipment) for expansion or modernization. It is ideal for small businesses requiring “brick and mortar” financing. Rather than commercial lending institutions, 504 loans are delivered via CDCs (Certified Development Com-


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DANIEL FORTE Technical Sales, 8 Year Veteran

W W W. E N C O N E L E C T R O N I C S . C O M

800.782.5598 SOLAR DESIGN

A FA B O O T H # 1 1 2 2 61


Nationwide Supplier Members Albina Pipe Bending Co. Inc. (866) 252-4628 Alku Group of Companies (800) 465-7143 Allen Architectural Metals Inc. (800) 204-3858

D & D Technologies (USA) Inc. (800) 716-0888 D.J.A. Imports Ltd. (718) 324-6871 DAC Industries Inc. (800) 888-9768

Alloy Casting Co. Inc. (800) 527-1318

Decorative Iron (888) 380-9278

American Punch Co. (800) 243-1492

DKS, DoorKing Systems (800) 826-7493

Ameristar Fence Products (888) 333-3422

E.G. Heller’s Son Inc. (818) 881-0900

Architectural Iron Designs Inc. (800) 784-7444

Eagle Bending Machines Inc. (251) 937-0947

Artist Supplies & Products (800) 825-0029

Elite Architectural Metal Supply LLC (847) 636-1233

Indiana Gratings Inc. (800) 634-1988 Industrial Coverage Corp. (800) 242-9872 Industrial Metal Supply Co. (800) 371-4404 Innovative Hinge Products Inc. (817) 598-4846 Interstate Mfg. Associates Inc. (800) 667-9101 The Iron Shop (800) 523-7427 King Architectural Metals (800) 542-2379 King Architectural Metals - CA (800) 542-2379

Precision Glass Bending Corp. (800) 543-8796 ProCounsel (866) 289-7833 Q-Railing USA Co. (714) 259-1372 Ransburg (800) 233-3366 Regency Railings Inc. (214) 742-9408 Robinson Iron Corp. (800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (800) 841-8457 Rogers Mfg. Inc. (940) 325-7806

Atlas Metal Sales (800) 662-0143


Banker Wire (800) 523-6772

ETemplate Systems (919) 676-2244

King Architectural Metals - MD (800) 542-2379

BFT U.S. Inc. (877) 995-8155

EURO-FER SPA (011) 39-044-544-0033

C.R. Laurence Co. Inc. (800) 421-6144

Sharpe Products (800) 879-4418

Big Blu Hammer Mfg. (828) 437-5348

FabCad Inc. (800) 255-9032

Lawler Foundry Corp. (800) 624-9512

Julius Blum & Co. Inc. (800) 526-6293

Feeney Inc. (Feeney Architectural Products) (800) 888-2418

Lehigh Valley Abrasives (908) 892-2865

South Camden Iron Works Inc. (800) 962-1029

(262) 786-9330

L.E. Sauer Machine Co. (800) 745-4107 SECO South (888) 535-SECO

Stairways Inc. (800) 231-0793

Gates That Open LLC (GTO) (800) 543-4283

Lewis Brass & Copper Co. Inc. (800) 221-5579

Geo. Bezdan Sales Ltd. (800) 663-6356

Logical Decisions Inc. (800) 676-5537

Stephens Pipe & Steel LLC (800) 451-2612

Glasswerks LA Inc. (800) 350-4527

Mac Metals Inc. (800) 631-9510

Sumter Coatings Inc. (888) 471-3400

The G-S Co. (410) 284-9549

Marks U.S.A. (800) 526-0233

TACO Metals (800) 653-8568

Hartford Standard Co. Inc. (270) 298-3227

McKey Perforating (800) 345-7373

Century Group Inc. (800) 527-5232

Hayn Enterprises LLC (800) 346-4296

Metabo Corp. (800) 638-2264

Transpacific Industrial Supply Inc. (909) 581-3058

Cleveland Steel Tool Co. (800) 446-4402

Hebo/ Stratford Gate Systems Inc. (503) 722-7700

Mittler Bros. Machine & Tool (800) 467-2464

Bridgeton Drafting Co. LLC (856) 205-1279 Byan Systems Inc. (800) 223-2926 The Cable Connection (800) 851-2961 Carell Corp. (251) 937-0948 Carl Stahl DecorCable Innovations (800) 444-6271

Colorado Waterjet Co. (866) 532-5404 CompLex Industries Inc. (901) 547-1198 Custom Mfg. & Polishing Inc. (417) 831-7900 Custom Orn. Iron Works Ltd. (866) 464-4766

Heritage Cast Iron USA (918) 592-1700 House of Forgings LLC (866) 443-4848 Hypertherm Inc. (603) 643-3441 Illinois Engineered Products Inc. (312) 850-3710

Multi Sales Inc. (800) 421-3575 NC Tool Co. (800) 446-6498 O.K. Foundry Co. Inc. (888) 592-2240 Ohio Gratings Inc. (800) 321-9800 Overseas Supply Inc. (866) 985-9885

Steel Masters Inc. (602) 243-5245

Tri-State Shearing & Bending (718) 485-2200 TS Distributors Inc. (800) 392-3655 The Wagner Companies (888) 243-6914 Wasatch Steel Inc. (888) 486-4463 Wiss Janney Elstner Associates Inc. (847) 272-7400

50TH ANNIVERSARY INVITATION to all of our affiliate organizations – Members of NOMMA, ASLA, ASTM, CLFMI, DASMA, IDA and NADRA qualify for AFA member rates on registration!


ER REGIST /11 by 12/21

January 25-27, 2012 Miami Beach, Florida

YOU’RE INVITED! NOMMA members range from artists to manufacturers who like American Fence Association (AFA) members, continually pursue setting the standard of excellence in their industry. Join us as we celebrate the 50th Anniversary of AFA and FENCETECH, the world’s largest fence, deck and railing tradeshow in 2012. Expand your interests and better understand the fence, deck and gate markets as a partner to your creations and products. There is no better place to learn about these new opportunities, and at this unique exhibition you will:

Find Cutting-edge Technology. Explore and compare first-hand the latest products and services in the industry to help expand your metalworking business.

Make New Industry Connections. Meet over 300 exhibitors who represent every market segment from fence, deck, railing, gates and associated products to high security.

Get Solutions. Receive valuable face-to-face time with manufacturers and suppliers who understand the industry and are ready to discuss your product specifications and challenges. Now you can register at AFA member rates (for qualifying affiliate organizations) for admission to the show floor and public demonstrations or a full convention package that includes seminars on fence, decking and access control materials and installation. For more information, visit or call 800-8224342 or 630-942-6598.


THANKS TO OUR 2012 SPONSORS Access Automation & Controls Group of LA • ci Fabrics • Country Estate Fence & Deck • Electronic Data Payment Systems • Encon Electronics • LiftMaster • Linear • Master Halco • Poly Vinyl Creations • Southwestern Wire



New Members We are pleased to introduce our newest members. We encourage our new member firms to “jump in and get involved.” New NOMMA Members as of October 21, 2011. AlumiWorks LLC Randleman, NC Wayne E. Parker Fabricator Anvil Craft Corp. Easton, PA Paul T. Sklodowsky Fabricator

Super Thanks!!! A thanks to all members who have contributed so far to our 2011–2012 membership campaign! We encourage everyone to sponsor a member and/or send the NOMMA office your leads.

Feb. 29 - Mar. 3, 2012 Orlando, FL

Provided NOMMA with a member lead n Stan Lawler, Lawler Foundry Corp. n Nancy Hayden, Tesko Enterprises n JR Molina, Big D Metalworks n Lynn Parquette, Mueller Ornamental Iron Works (2)

B & O Machine Welding Brookhaven, MS Charles Perez Fabricator

n Gregg Madden, Madden fabrication (2)

Tacoma Iron Work Tacoma, WA John Leskajan Fabricator

Sponsored a member

option 1

METALfab 2012

Catch the energy! Make plans now.

n Rhoda Mack, Fine Architectural Metalworks

n Julius Blum & Co. Inc. n FabCAD

NEED COMMERCIAL INSURANCE? NOMMA and Industrial Coverage Have Hammered Out a New and Improved Program Just For You! Tools for a Custom Fit: Property & Equipment Coverage General & Products Liability Vehicle Insurance Umbrella Liability Worker’s Compensation

Industrial Coverage Corp. has been NOMMA’s trusted Insurance consultant and advisor since 1989. I.C.C., under the guidance of NOMMA, has created a specialty insurance plan specifically designed for Ornamental Metal Fabricators.

Call the Ornamental Fabricator HOTLINE for competitive pricing on custom quotes at 800-242-9872. Or visit us at our website: option 2 November / December 2011 n Fabricator

NOMMA and Industrial Coverage Hammer


What’s Hot? n People

Gary Parks named manufacturer’s rep for CML USA Ercolina

Gary Parks will serve as Ercolina’s new manufacturer’s representative at CML USA Inc. He will be responsible for covering the northern portions of California and Nevada. CML USA is a manufacturer of tube, pipe and profile bending and metalworking machinery. Parks has 27 years of metalworking and fabricating sales experience.

Jorge Reyes joins Direct Metals sales team

Jorge Reyes has been named to the inside sales team of Direct Metals Co. He will be responsible for quoting custom and stock items of bar grating, perforated metal, wire mesh, expanded metal, safety grating and fiberglass grating. Reyes brings business and management education experience, as well as previous sales experience in the construction industry. Reyes studied accounting at Miami Dade College and has a bachelor of science degree in construction management from Southern Polytechnic State University.


Industry News

Feeney installs solar array in Oakland Feeney Inc., Oakland, CA, has installed a 90-kilowatt solar system capable of generating over 95% of its current energy demands. Feeney is a U.S. manufacturer of high-quality stainless steel architectural cables, aluminum railings, and trellis products, including cable railing infill product CableRail. The new installation consists of a 5,000-square-foot solar array on Feeney’s two buildings: one with an 18-degree standing seam metal roof; the other on a flat membrane roof. Both roofs support arrays of 190 SunPower 238-watt panels, each serviced by a Satcon 50-kilowatt inverter for a total of 380 panels with a rating of 90.4 kilowatts DC. “This solar energy project is part of an overall commitment that we’ve made as a company to environmental responsibility, from the use of recycled materials in our products to the efficient

use of resources and energy in our operations,” said Andy Toimil, Feeney’s vice president of operations. “The machining of metal parts is energy intensive and our team is incredibly proud to do what we can to make our operations more environmentally efficient. This solar installation is another step in that direction.” “In addition to the environmental benefits, as a California-based company, it was important to us to find a local installer for this project to help support our state economy,” said Andrew Penny, Feeney’s vice president of marketing. “We were pleased to find an installation partner and product provider that met those needs.” The project was handled by Solar Technologies, of Santa Cruz, CA. For more information, go to www.

The Cable Connection gets LAX contract The Cable Connection, Carson City, NV, has won an order to machine fittings and manufacture cable assemblies for use in the Bradley West portion of the Los Angeles International Airport’s Tom Bradley International Terminal. The new Bradley West 15-gate concourse can accommodate passengers arriving and departing on the giant new Boeing 787 Dreamliner and Airbus A380 airliners. The assemblies, comprised of a combination of The Cable Connection’s Ultra-tec components and custommachined components, will make up the assemblies being installed overhead along the pathway between the plane

and customs areas for security purposes. The Cable Connection’s CEO, Lou Marino, said that the contract “required a combination of some of our existing Ultra-tec product line, our ability to custom machine components per the architect’s requirements, and our in-house team to design some completely new fittings.” The Cable Connection’s Ultra-tec cable railing product line is specified frequently for large projects, according to Reed Construction Data, which provides construction project leads throughout North America. The company also serves multiple market segments, including retail and DIY. Fabricator n November / December 2011

What’s Hot? n


Metal Arts center offers forging, patina classes The Center for Metal Arts, Florida, NY, continues its fall/winter session with classes in basic forging, forging nonferrous metals, and creating patinas. Dec. 10, 2011 Fundamentals of Forging Instructor Vivian Beer offers technical knowledge and hands-on time. Students are provided with the forge, their own anvil workstation, tooling, an authentic Hofi hammer, and plenty of stock to forge. Feb. 25, 2012 Forging the Nonferrous Metals Instructor Darren Fisher teaches forging of silicon bronze, brass, copper, and aluminum. Students wanting to forge sterling silver may bring supplies for specific silver-working instruction.

November / December 2011 n Fabricator

Basic working processes, such as annealing, work hardening, and tool prep are covered. The class features jewelryscale forging, but can include smaller architectural pieces, such as knobs and handles. Techniques will focus on a few simple hammers and one forming stake. March 17, 2012 Patinas for the Small Studio Instructor Darren Fisher will discuss patination of copper-based alloys. Most of the patinas will use color via chemical reaction, not paints and stains. Texture demos will help develop patinas more, and simple patinas in silver and steel may be covered. Safety and proper chemical handling will be discussed. Contact the Center for Metal Arts, 845-651-7550 or 888-862-9577; www.

Event Dec. 9–11 2011 Blacksmithing class Pieh Tool Company will hold one of its beginner/intermediatelevel blacksmithing classes in Camp Verde, AZ, near Phoenix. Instructor Gordon Williams leads students in the basic techniques of blacksmithing, traditional joiner, forge welding, and tool making. The facility has fully equipped workstations, and students will take home finished projects. Class size is limited to six students. Contact Pieh Tool Co., 888-7434866;


What’s Hot? n Catalog of architectural metal products, railings The Wagner Companies The 2012 master catalog from The Wagner Companies is now available, including all railing systems, products and services in a 304-page directory of more than 7,800 standard catalog items. The new catalog introduces a number of new products and services including the Slip-Fit Railing System, Kalamazoo Aluminum Ball Style Railing, Bantam LED Mini Spot light, swageless cable rail assemblies, Spiral Stair kits, and Glass Spiders and fittings for structural glass installation. Also featured are components added


to the PanelGrip dry glaze glass railing and cable railing systems. The new catalog also includes an expanded technical information section that provides installation instructions and current code summaries. Contact The Wagner Companies, 888-243-6914; www.wagnercompanies. com. OSHA training guide Blue Gavel Press Blue Gavel Press has released the 13th edition of the OSHA Training Guide to provide employers with a framework for safety training. It features the most current safety training information, compiled and explained in everyday terms. Highlights of the latest edition include a new training module, new quizzes, and a revised employer

checklist. The guide was developed and updated by expert legal authorities and compliance specialists. While the OSHA Training Theresa Jones, CEO Guide provides a of Blue Gavel Press. basic foundation for safety training, says Theresa Jones, CEO of Blue Gavel Press, the materials must be modified to meet the particular needs of each workplace. “There is no such thing as a ‘typical’ employer,” she added. “Every workplace is unique, as are the training needs of its workers.” Contact Blue Gavel Press, 800-4172669;


Proven design Efficient-Reaches 2350 Degrees Versatile Portable Many Models Available

Call for Free Catalog - 800/446-6498

NC Tool Company Inc 6133 Hunt Road Pleasant Garden, NC 27313 336/674-5654

Restoring the Past. Building the Future. Questions? Call Peter H. Miller, President: 202.339.0744 x 104. Or email


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What’s Hot? n


Light towers for hazardous locations Larson Electronics’ Magnalight Larson Electronics’ has a new line of light towers designed to improve deployment ease and fixture mobility. Equipped with two 400-watt metal halide lamps mounted to an aluminum frame, the HAL-2X400MCE extendable wheeled light tower illuminates 50,000 square feet of workspace. The wheel base is 39-inches x 35-inches. Rated Class 1, Division 2, this hazardous location light tower can be extended to 8 feet for maximum coverage and collapsed to 5 feet for easy transport. The base design allows the user to tilt the unit back while extending the

tower to its full height, setting the lock pin, and then tilting it fully upright for secure placement. The two metal halide lamps include multi-tap ballasts, allowing the unit to be configured for use with current ranging from 110VAC to 277 VAC using jumpers. The lamps are encased in powder-coated assemblies with tempered glass lenses for durability. The towers also include anti-static tires and 50 feet of yellow SOOW, abrasive and oil resistant cord terminating in an ECP 1523 Class 1 Division 1 explosion-proof straight-blade plug. This light tower is UL approved for marine and wet environments and suitable for open areas where flammable gases and vapors may be encountered. Contact Larson Electronics’ Magnalight, 800-369-6671; www.magnalight. com.

Plasma cutting systems Thermal Dynamics Thermal Dynamics, a Thermadyne brand, has added the UltraCut 400 to its line of high-precision automated plasma systems. This product is designed to deliver 400 amps at 200 volts at 100% duty cycle. It offers production piercing and cutting up to 2 inches on mild steel, stainless steel and 21/4 inch aluminum. All Ultra-Cut systems include the Water Mist Secondary process for precision cutting of nonferrous materials. The Ultra-Cut line has two additional sets of dedicated robotic consumables. These new 15- and 30-amp conpresents











PHONE: 1-800-888-9768 INDUSTRIES, INC. FAX: 616-235-2901 600 ELEVENTH ST. N.W. GRAND RAPIDS, MI 49504


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2011NOMMAFabricatorNovDecIssue.indd 1


12/3/10 1:07 PM

What’s Hot? n


sumables are designed to deliver excellent cut quality on thin gauge mild steel and increased parts life, says the company. Along with these offerings, Thermal Dynamics has introduced its new Diameter Pro technology with its XT-Series of CNC controls, to deliver quality holes and reduce hole taper to a minimum. It optimizes hole quality in mild steel on 10 gauge to 1 inch from a 1:1 diameter to thickness ratio and larger holes. Contact Thermadyne at 800-4261888; Stainless and aluminium gate handles Jefco Mfg. Jefco Mfg. has introduced a new line of stainless steel and aluminum handles (7/8 inches wide), available in

three sizes (5 inch, 7 inch, and 9 inch). The stainless steel handle has a brushed finish and the aluminum handle has an anodized satin clear finish. Manufactured from heavygauge material for strength and durability, all handles have four mounting holes (two on each end) and can be used vertically or horizontally. Custom materials and finishes are available. Contact Jefco Mfg., 954-527-4220;

gate closers for the commercial industrial industry — the SureClose Adjustable Gate Closer and Hinge. These hinges are designed for style and durability, with aircraft-grade aluminum and stainless steel components. The hinges test to 500,000 cycles with a 1,500-pound load capacity. SureClose can replace conventional hinges, closers, and header arrangements in a noninvasive process, hiding the hydraulics inside the fence post. The aim is to provide greater strength without additional installation time or hardware needs.

Concealed hydraulic hinge gate closers D&D Technologies D&D Technologies has introduced a line of concealed hydraulic hinge

Infill Panels

TUBING BENDERS Hand Tube Bender Rolls:  1 1/2” Square Tubing  1 x 1 1/2” Rectangular Tubing  Flat Bar (1/2 x 1 1/2” & smaller)  Pipe & Tubing


Rectangular Mesh

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 2” Square Tubing 1 x 2” Rectangular Tubing

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We will custom fabricate infill panels to meet your specific requirements. Available in diamond, rectangular and square mesh with or without standoffs. Frames available in 1" x ½" channel or with a hemmed edge. Division 5,8 and 10.

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 Flat Bar (on edge hard way) R&D Hydraulics, Mfg. and Machine Co. 1431 West 5th St. Chico, CA 95928 70

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96 1-800-609-82 View our complete catalog ate .com nlin www.JescoO Jesco Industries, Inc.

950 Anderson @ Fab Road Litchfield, MI 49252-0388

Phone: 1-517-542-2353 Fax: 1-517-542-2501

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What’s Hot? n


SureClose comes in five models that can be face-mounted or centerline-mounted with adjustable selfclosing speed. Some models feature final snap action for overcoming electric locks. Each hinge comes with its own adjustment tool in the box and bracket. D&D suggests applications for these products ranging from government institutions, military training bases, airports, theme parks, hotel/motel properties, playgrounds, schools, sporting arenas, and high-end residential pedestrian and double drive gates. Contact D&D Technologies, 800716-0888; Blacksmithing hammers Pieh Tool Pieh Tool has introduced a line of blacksmithing hammers in the Pieh

November / December 2011 n Fabricator

Legacy Collection. The new hammers come in seven styles. The Ergonomic Diagonal Pein Hammer is available in the 21/2-pound size in both left- and right-handed styles. The Ergonomic Straight Pein Hammer is available in three sizes: 11/2, 21/2, and 31/2 pounds. The Ergonomic Cross Pein Hammer is available in four sizes: 11/2, 21/2, 31/2, and 41/2 pounds. The Ergonomic Rounding Hammer is available in four sizes: 2, 21/2, 31/2, and 4 pounds. The Ergonomic line of hammers is made from 4142 tool steel, hardened to a Rockwell 52. Handles are 12 inches

long and custom fit from straightgrain aged hickory. Also new to the Pieh Legacy Collection are the Pieh Standard Cross Pein and Standard Straight Pein Hammers, both available in 11/2 and 21/2-pound sizes. The Standard Rounding Hammer is available in 11/2, 2, and 21/2-pound sizes. The Standard line of hammers have 15-inch handles and are hand forged from 4340 tool steel. Contact Pieh Tool Co. Inc. 888-7434866; Grinding and deburring tools Dapra Dapra’s series of Biax hand-held, air-powered tools include lightweight grinders and variable-speed deburring machines, including the SRD 3-55/2 and SRD 6-30/2, for grinding and shaping.


What’s Hot? n

The SRD 3-55/2 features a lowvibration motor for fine deburring and long service life. Its rotational speed is 55,000 rpm with an air consumption of 6 cfm. The SRD 6-30/2 high-performance grinder has a 150-watt motor and achieves a speed of 30,000 rpm. Both lightweight grinders have twist valves and are designed to reduce user fatigue. Dapra also offers straight and angled variable-speed, hand-held deburring tools. The angular design of models BEW 309 and BEW 605 is


designed for deburring bore holes in difficult-to-reach areas, such as slanted bore holes that must be deburred from the inside. The BEW 309 has a variable speed of 0-900 rpm; the BEW 605 has a variable speed of 0-500 rpm. Both models have a lever valve and a backward air exhaust direction. The Biax BE 309 straight drilling/ deburring machine deburrs bore holes up to 5.5 mm and has a variable speed of 0-900 rpm. The tool has a pushstart valve. Contact Dapra Corp., 800-2433344; Vertical column cold saw Kalamazoo Machine Tool The Kalamazoo Machine Tool Model C320SA vertical column cold saw is designed for semi-automatic operation for production sawing of

tubes, profiles and small solids. The saw features two spindle speeds, 17 and 34 rpm, and accepts blades up to 121/2 inches in diameter. The operator controls are designed for fast setup, and feature powered vise and powered downfeed control. Standard equipment on the C320SA saw includes a heavy-duty precisionground saw bed, TEFC 3-phase, 21/2 hp drive motor, totally enclosed transmission and full blade guarding that is easily removed. All electricals meet NFPA-79 electrical standards. Contact Kalamazoo Machine Tool, 269-321-8860;

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Association of North America, Inc. 72

Engaging hands and hearts since 1925. Come enjoy making crafts and good friends on 300 natural, scenic acres in western North Carolina.


1-800-FOLK-SCH NORTH CAROLINA Fabricator n November / December 2011


Advertiser’s Index A thanks to the following advertisers for their support of O&MM Fabricator magazine. Pg Company


64 American Fence Association Inc...............................................www. 38 Apollo Gate 39 Apollo Gate Operators 14 Architectural Iron Designs 72 Artist-Blacksmith’s Assoc. of North America 67 Atlas Metal Sales............................................. 13 Big Blu Hammer Mfg. Co. / Oak Hill Iron 31 Blacksmiths Depot / Kayne & Son Custom Hardware Inc...................... 32 Julius Blum & Co. 36 The Cable Connection................. 72 John C. Campbell Folk 58 Carell Corporation........................................... 7 Chicago Metal Rolled Products Co...................... 60 Colorado Waterjet 56 CompLex Industries 55 CS Unitec Inc........................................................ 49 D & D Technologies (USA) Inc............... 9 D.J.A. Imports Ltd........................................... 69 DAC Industries 71 Doringer Cold Saw............................................. 37 Eberl Iron Works 61 Encon 29 FabCad Inc............................................................... 33 Feeney Inc. (Feeney Architectural Products)..................... 43 The G-S Co.................................................................. 51 Hebo - Stratford Gate Systems

Your advertising contact for O&MM Fabricator NOMMA Buyer’s Guide NOMMA website CO NTAC T

Sherry Theien

Advertising Director 8392 Leesburg Ct. Rockford, IL 61114 815-282-6000 815-282-8002 fax

November / December 2011 n Fabricator

  Pg Company


71 Hougen Mfg. Inc................................................... 65 Industrial Coverage Corp............... 44 International Gate 76 The Iron 60 Jansen Ornamental Supply Co.............. 70 Jesco Industries Inc. WIPCO div................ 50 Kalamazoo Machine Tool.................................. 75 King Architectural Metals............................. 3 Lawler Foundry 2 Lewis Brass & Copper Co. Inc..................... 69 Lindblade Metal 46 Marks 41 Metabo 48 Pat Mooney 68 NC Tool Company 70 R & D Hydraulics Mfg. & Machine 35 Regency 43 Rogers Mfg. Inc........................................ 26 Scotchman Industries................................... 47 Sharpe Products.................................... 53 Simsolve................................................................ 62 Stairways 59 Sumter Coatings 50 TigerStop LLC....................................................... 68 Traditional Building....................... 28 Tri-State Shearing & Bending.................................... 718-485-2200 67 Universal Entry Systems Inc.......................................216-631-4777 42 Vogel Tool & Die Corp...................................... 4 The Wagner

Advertise in the 2012 NOMMA Buyer’s Guide Your one-stop resource for shop and office personnel The Buyer’s Guide is available in 3 versions: 1) print, 2) online, and 3) database. Closing date November 30, 2011 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; 73


Metal Moment

Humbling creations Editor’s note: We are pleased to feature samples of our reader’s work. This issue, meet Clyde Pennington, owner/artist of Intuitive Iron, Indianapolis, IN. Starting out as a carpenter, Clyde loved metalwork too. He bought a plasma cutter and welder to begin experimenting. Soon he got commissions. After working with a business partner for several years, he went solo. Recently, he opened a school for students to craft their dream project. He also teaches. “I just really love designing and creating unique pieces, and I’m humbled that people actually pay me to do it,” Clyde says.

For more information: 317-289-8269;

Console Table

The top of the table is two-inch black walnut and the branches pierce the wood. The tree trunk is made of 1/8-inch plate. A mix of ½- and ¾-inch round stock was also used. Some 3/8-inch stock was chased out to create the vines. The finish is a hand-rubbed patina stain. “I’m really happy with the overall feel and finish of this one. It’s found a great home in beautiful Jackson Hole, WY.”

Aluminum Bench

Cowboy Hat

The hat was made with stock that was slightly heavier than 16-gauge sheet steel. The piece was forged with a Johnson gas forge and oxyacetylene with a rosebud torch. The finish is a semitransparent black stain, hand rubbed.

The client had a 100-year-old glass panel from an old church and wanted it incorporated into the bench. After countless hours of fabricating and polishing, this oneof-a-kind bench was born. The project was sketched out and cut from 1/8-inch to 3/16inch aluminum sheet, and the seam 100% percent welded. The seat was ergonomically designed to fit body curves. “It’s not only got to look good, but it’s got to feel good,” Clyde said. The finish was done with linear and circular grinding tools. A second glass panel was used for a yard sculpture.


Something on your mind? Got something to say? Got an idea? Got a tip? Got a gripe? Do you have a story to tell? Fabricator magazine would like to interview you for a Metal Moment story. Please contact editor Todd Daniel at 74

Fabricator n November / December 2011

November / December 2011 n Fabricator


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or visit our Web Site at Fabricator n November / December 2011

2011 11 fab  
2011 11 fab