Custom Designed Door Hardware some common misunderstandings

During the Covid lock down and after weeks of cooking and reading many turned their energies to drawing designs on their mobile devices and in their sketch pads.

This explains why there has been a flood of emails from consumers and the occasional designer who have an idea for a custom door handle they would like made. In the next few posts, I will be tackling the progressive stages involved from taking a design idea to creating a functional door handle or door pull. These 2 types of hardware are not synonymous as a door handle needs to be designed and engineered so that the knob or lever parts can turn and latch whereas a door pull has no moving parts.

So, let’s begin with the design process and see what needs to be considered.

One design still on the drawing board

Martin Pierce is constantly drawing ideas for door pulls and these typically start with a doodle or sketch done old style with a pencil and sketch book. Many of you will be equally skilled using your mobile device to create a digital drawing and we can consider these provided they are either pdf or jpegs. Regardless of medium the sketch will only be useful if it includes a profile or side view that shows the shape and curvature of the piece and whether it is suitable to work as a grip or pull for your hand (see the palm tree design above) . If you can’t visualize and accurately draw the profile, then it is time for you to re-think your hobbies. However, if you think your design does have potential then please make sure to copyright it even if this is the home version of mailing yourself a copy noting the date and with your signature.

For the ambitious who set out to design a handle they must also design the rose or back-plate. If the handle is to be fixed, then the task is easier as the rose/plate simply must be wide enough to be fastened to the door with screws that will attach both the rose and the knob or lever that will be welded to it. The back-plate and knob/lever are separate castings, and I will explain in a subsequent post why they cannot be created as one casting as well as what additional design drawings are required for a functional door set.

The scale and dimensions of your handle need to be added to your design including the depth for your profile. The depth or thickness of your design will have a direct impact on the weight of the cast handle. The heavier the piece the higher the cost as more bronze or stainless steel will be used in casting.

Making a door handle black - patination versus powder coating

Alloys like steel and bronze can be colored by immersion in a chemical patina such as the M20 chemical from Birchwood which is suitable for bronze or by baking on a layer of pigment powder to the surface of the handle. Neither method is superior to the other, but both have different benefits.

316 Stainless steel is better suited to powder coating as this type of steel is hard, dense and corrosion resistant making it difficult for chemicals to penetrate or to form a chemical bond with. Our Morphic and Ergo collections are typically cast in 316 stainless steel an alloy that lends itself to contemporary door handle designs.
Copper is the primary metal in bronze, and it will readily react and oxidize when exposed to acidic chemicals to form a new micro thin layer. The color that develops through this conversion of copper will depend on the chemicals used and the colors can range from blue greens to red browns to black.  To create black, we use M20 a product made by Birchwood Technologies and one that contains selenious acid which is the component that oxidizes the copper turning it brown or black depending on the number of applications and length of each treatment. As the depth of color can be built up over several immersions it is method well suited to a patina where you want a range of color and a more organic appearance. As the patina is micro-thin several layers can be built up and then sanded back to reveal a range of color. If a uniform effect is wanted then the handle can be immersed in a bath of this solution several times to develop an even color of the required darkness.

By comparison powder coating works well on 316 stainless steel as the pigmented layer is baked on to the surface of the piece and no penetration of the surface occurs. Powder coating offers a wider and more controllable range of color and luster with a wide range of standard colors and custom mixes available from companies like Prismatic who offer a choice of over 6,000 colors. https://www.prismaticpowders.com

Wine Cellar Door Handles and Shell Casting

All of our smaller cabinet pulls and many of our slim elongated handles are cast in solid bronze or stainless steel but other pieces, including the Grapevine Heroic Pull are cast using a hollow shell to create a hollow casting. The complexity of the design and the weight of the alloy determine whether the piece is to be cast as a solid handle. For example, the ergo extended pull is 35” and the Grapevine is 42” but the Ergo pull would be prone to warping if it were a hollow casting but being a little slimmer when cast is a manageable 10.5 lbs. By comparison, the Grapevine handle is considerably longer but because it is hollow cast is only 1lb heavier.
In a previous post I described how a wax pattern is made and how the location and number of wax runners and gates determine how the wax and subsequent bronze will flow. Whether the casting is a success will also depend on how the piece is shelled and how the shell is subsequently removed.

3 Wax Sections - Access Holes Added to Each So That The Hard Shell Can Be Removed From the Inside of the Castings

The wax replicas are repeatedly dipped into a fine ceramic slurry. The slurry needs to be fine to capture the detail on the surface of the wax replica and enough coats need to be built up to form a strong wall casing around the wax. The outer layers of the slurry are reinforced with coarser fibers that help create a stronger wall. The shell is then fired to create an extraordinarily strong casing and the wax is removed leaving the shell hollow and ready to receive molten metal. Once cast the shell will be broken off and the casting will be ready to finish.
The Grapevine handle is cast in 3 sections with 3 hollow waxes making 3 bronze castings that are welded together to create one handle. As the entire inside and outside surface of each wax section will be encased in a ceramic shell, we created holes or patches in the wax as access points. These holes or patches were also shelled and then cast in bronze. After the bronze castings were poured, we were able to remove the hard shell from inside the casting by sandblasting the interior through the access holes. The bronze patches or plugs are then welded onto the casting the 3 pieces are welded together and the welding joints are tooled by hand to create a seamless piece.
Each wax section of the Grapevine handle required 2 to 3 patches.

Access Holes Created In the Wax - The Removed “Patch” Is Cast In Bronze - Patch Seamlessly Welded In Place

Early Designs for A New Entry Door Pull

In May of this year we began to extend our orchid collection of cabinet pulls to include corner pieces and taller vertically positioned pulls and these can be seen in an earlier post. These earlier pieces work well as cabinet pulls and for interior doors but for an entry door we felt their scale was too petite and so began designs for a new door pull that would be substantial enough both physically and aesthetically for larger and heavier entry doors.

We wanted to continue the orchid collection using the same type of orchid bud but designed 2 leaf components for strength and also for style. The leaves are a departure from our other orchid designs and their fleshy appearance and channeled surfaces will provide a finishing point on the door face.

Carved in basswood, Martin sculpted a total of 5 orchid parts as patterns for his latex molds. The flower bud was carved in 2 parts, one part for the petals and one for the stamen. The petals and stamens will be cast separately and only later will they attached when the bronze castings are eventually welded together as a sculptural orchid handle.

The images shown here are scans of drawings from Martin’s sketch book which he keeps on hand at home to jot down ideas as they develop. By drawing a front and profile view Martin is able to plan how to deconstruct the design so that each section can be finely carved and so that each pattern can be easily molded with well positioned gates. The location of the gates will be critical if the wax is to flow easily without bubbles creating small voids.

The Urban Forest of Los Angeles

Before the city of Los Angles was veiled in a thick blanket of smoke from the Bobcat and other countless regional fires our daily walks would take us through the urban forest that beautifies this densely populated city. The rich variety and density of the tree population provides more than aesthetic relief but is a powerful tool in the fight against green-house gas pollution and rising temperatures.
The urban forest in Los Angeles is estimated at over 1 million trees, many are in the parks in and around the city but an increasing percentage are being planted and nurtured in streets within neighborhoods.
Organizations like our local Tree People work with tree deprived neighborhoods in planting and maintaining young trees during the first few years of their growth and the trees planted around our studio over 15 years ago are now vibrant and mature.
The well-being and continued growth of this forest benefits all who live here as the trees absorb carbon monoxide, sulfur dioxide and ground level ozone converting them through photosynthesis into oxygen making the air breathable at least some of the time. In Los Angeles County from Los Angeles city to Pasadena our current level for these pollutants is running from 165 to 279 on the AQI index or from poor air to hazardous air depending on proximity to the burn zone.
The tree canopy of our urban forest also helps mitigate some of the heat gains of global warming by providing shade and thereby reducing our energy consumption.
The Jacaranda tree we planted on our sidewalk and the succulents that surround it were one of our earlier investments into creating a small drought sensitive and shady sidewalk space.
The vertical wall that separates our studio from our neighbor became a vertical garden when we planted a ficus vine. This rampant plant has clung to the face of the concrete wall adding color to a boring grey backdrop as well as filtering the surrounding air.

Hedgerow Bronze Trees using the Ficus Vine at our studio as a canvas

The Camphor tree has powerful roots but a more creative approach to sidewalk repairs and new sidewalk planning can incorporate tree roots through with sidewalks that meander around the trees root berm.

A fifteen year old Jacaranda tree helps provide shade

Door Handles For Yachts - 316 Stainless Steel Passivation versus Rust

In a previous post we analyzed the components of grades 304 and 316 stainless steel that make them rust resistant. Both contain chromium, and nickel and together these elements enable the outer surface of a casting to form a thin protective layer of chromium oxide that protects the lower surfaces and acts as a barrier to rust. However, only 316 stainless steel contains molybdenum which is a metal that specifically helps prevent rust caused by exposure to sea water or sodium chloride which is why this is the preferred steel for yachts and beach homes and why it is aptly described as marine grade stainless steel.
While 316 stainless steel in its production contains the necessary properties to prevent corrosion the thin nano thick protective film can be degraded and while the presence of nickel does help this layer self-heal and re-form the protective chromium oxide there may be occasions when the fixture will need to be treated.
Several years ago, we heard from a homeowner in Florida who reported that her 316 stainless steel handles was developing rust. On inspection we could see that sand and grease had adhered to the handle and it was these contaminants that were rusting. The handle itself was still sound and showed no structural decay, in other words, the steel was not actually rusting.

Morphic Entry Lever In 316 Stainless Steel Compare With Similar Handle After 10 Years In Image Below

This type of surface contamination can also occur when the stainless steel is machined especially if there are iron based metals in close proximity.
In both cases the surface can be cleaned or “passivated” by being immersed in a citric acid solution which will remove most contaminants and allow the surface to self-heal by forming a new passive layer of chromium oxide. I strongly recommend that you do not do this yourself but find a reputable passivation company in your area.

Morphic Entry Lever With Blue Powder Coat 10 Years After Installation

Marine grade steel is not only durable, but it polishes well and can be enhanced by using different finishing techniques or by adding color through powder coating. Powder coating is a durable way to add color to any stainless-steel fixture especially if it intended for outdoor use.

Neptune's Treasure - Ocean Front Door Handles

The scroll serpentine handle was designed for Baha Mar, a beach front resort in Nassua the Bahamas and was created in response to a request from Michael Hong Architects who were the architects and designers for this project. The long curvaceous pull is part of the Morphic collection but the coral inspired design needed to better capture the oceanic nature of this resort. We chose to fashion the ends of the pull on the moon snail shaped seashell thereby making the piece more like the trident spear used by Neptune God of the Ocean in classical mythology.

The oceanic theme was further reinforced by a blue powder coat which we added to inside of the handle. At a height of 40” the new piece was appropriately scaled to suit the grand entry doors to the SLS resort Hotel.

The handle is cast in 3 sections and the 2 scroll ends are welded to the coral stem to form a seamless piece. Cast in stainless steel, the handle is both durable and rust resistant and as with all exterior hollow vertical grips there is a “weep” hole at the lower end for rainwater to drain through.

We are currently completing an order for this piece and have been inspired to design a new set of handles using the snail shaped ends. The scroll ends will be free standing handles and at a height of 6” will be well suited for more modestly scaled residential entry doors. Stay tuned to see or perhaps sea how this piece evolves.

When Creative Minds Collaborate

The result can be a wonderful surprise as I just discovered when I came across the entry way door to an Encinitas residence designed by the very talented Joseph McCarter, the Principal Designer at J.W. McCarter & Associates. I happened upon a close-up shot of our green patina lizard set which was posted on Instagram and reached out to JWM to find out more.

What I discovered was an entry way grand in scale that seamlessly married the skills of wood artisans, glass makers and bronze sculptors to create a unique entry experience. The close up shot of the Lizard handle set only hints at the puzzle like design of the door and frame that was Joseph McCarters’ creative solution to a shortage of long boards of Mahogany.

See More from Our Lizard Collection

Photographer Nader Essa, Photos Courtesy J.W.McCarter & Associates

The puzzle design accentuates the scale of the entry and it is a playful theme that is carried through with our whimsical gecko pull mounted as an incidental accent on the right side of the door. Nature is clearly the driving force for this entry statement and the tropical monstera adansonil “cheese plant” fabricated in stained glass by Glass Light Studio is the vine that weaves from the top to the bottom of the door tying together the parrot, gecko and lizard.

The entry door acts as a bridge from exterior to interior. The grandeur of exterior is achieved in part through the scale of the mahogany puzzle sections and by the upward shining light manufactured by ELA. The treatment of the door interior is more familiar with the door being integrated with the surface of the interior walls and mounted art.

The photographs shown here are courtesy of J.W. McCarter & Associates and the photographer was Nader Essa who specializes in architectural and interior design photography

The door was fabricated by Busch Woodworking.