Fire Place surround

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This is going to be a hinged fire place grill/surround combo. Mostly 16 ga. sheet. with some other odd stuff thrown in to jazz it up.The grille is a funky angular sort of random pattern and will be 1/4 and or 3/8 inch round bar.The fireplace is a direct vent gas with a glass front that slides out from the top of the face. Luckily than means all my stuff has to do is swing out of the way so the glass can be removed for service.So if you were standing in front of the fire this thing is raised 1-1/4" off the wall by the sides, it will be hinged on the left and have magnetic latches on the right. When its closed the latches and hinges will be hidden so it will look like it's permanently fixed to the wall.width- 42" inside, 58" outsideheight 32-1/2 " inside, 48-1/2" outsideEdges broke to 1-1/4" @ 90*Will be painted flat black.Cut cut cutBend bend bend. How do you like my poor mans metal brake. Grind a little relief cut on the back flip, line up with the edges  of the table and bend away. Take your time keep it even, then check it with a square when you're done.Last edited by app-ironworksllc; 11-12-2009 at 09:19 AM.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Here's where we're at this am. Time to get to work see youns later.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Keep the pictures coming. Did you cut it out with the grinder/cutter?
Reply:oh boy, i'm looking forward to this, app does great work
Reply:Just about got her licked.Framing is pretty much done. Just need to bring in the belt sander tomorrow and even up the outer lip. Then build the grill, hinges and latches , paint and install, and she'll be done. Looking like install on Monday.Here's what I cut it out with, worked great and gave a nice clean edge with minimal deburring necessary.Framed the inner lip with 1/4" x 1" h.r. flat bar and rolled the sheet around to give a nice clean edge. Surprisingly, one added benefit of hammering this stuff for almost 2-1/2 hours straight is that it really reduced any pent up frustration I've been carrying around.I think I can get along pretty good seeing as I am no tin bender and have no shear or brake to make this real simple. Like everything else I do, I'll figure out a poor boy way of doing it if possible.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:NICE WORK  will you install as one unit. or put in as section's and finish on site? bender set up look's good.
Reply:Nice job. It's nice to show some guys that you don't need the newest and fanciest gadgets to do some things. Yeah it takes time, but you can still get really nice work if you think a little and take your time.I noticed at first the bends on the corner of the table and thought how nice and straight you did them. I wouldn't have guessed the air chisel to do the cuts. I would have bet on a grinder and slitting wheel. You got a nicer finish with that than I would have thought. Never did much with that bit on mine. Usually just used it to beat off rivets or toss on the  needle scaler on my air hammer. I'll have to play a bit with it some time..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I've got to do one of these for our new house sometime soon.But I don't think ours has to have any hinges or anything.  Just a standard surround. Thank goodness.  Looking forward to more progress pics.
Reply:great post, i always learn from you. is that 16 ga hot rolled black (uncoated )steel?
Reply:Originally Posted by weldbeadgreat post, i always learn from you. is that 16 ga hot rolled black (uncoated )steel?
Reply:dos questions-in the inside corners why is the 16 ga cut on an angle where it wraps around the flat stock..?doesnt that expose the flat stock to view?where the 16 ga meets in the middle ,there is a piece of plate between the flat stock..hows come the 16 ga has a gap there?
Reply:Originally Posted by weldbeaddos questions-in the inside corners why is the 16 ga cut on an angle where it wraps around the flat stock..?doesnt that expose the flat stock to view?where the 16 ga meets in the middle ,there is a piece of plate between the flat stock..hows come the 16 ga has a gap there?
Reply:App Ironworks is a class act.Excellent!
Reply:Thanks Johnny.Got a little done today. All the edges are cleaned up. Ready to start figuring out the grill pattern and hinges next.If the customers like this pattern I'll take no time to finish up the grill.While I'm waiting on them I'll start figuring out the hinges and latch brackets.I would have got more done but I spent some time working on a bid for 200 l/f of hand rail that a local builder called about.Last edited by app-ironworksllc; 11-13-2009 at 05:36 PM.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Got some more done. I had to redesign the grill to be organic and twig-like. HO's loved version2.0.Redesigned grill.Figuring out the pieces parts. Cut the bar and laid it in order to start bending. One of my friend/peer/coworkers makes joke about me "super analyzing" my work. I'll give him that, but after having worked for one guy who screwed up almost every job I got very tired of building every project 3 times. So I do try to take a little more time during the math-a-lysing and layout.I love my bender. I don't care who you are, for versatility there's none better then the Hossfeld no. 2Once I got to bending pieces it went pretty quick.Last edited by app-ironworksllc; 11-18-2009 at 01:27 PM.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:All tacked up. I took it out to weld and grind so it wouldn't get the sheet metal all messy.About got her licked at this point. A little clean up and finish the hinges next.Since this one is being used for a  direct vent gas log fireplace with a glass front it wont get any screen.Last edited by app-ironworksllc; 11-18-2009 at 01:24 PM.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:That looks really nice.  I wish I had a fireplace to make a surround for...Miller Millermatic 212... and that's about it... for now...
Reply:Well I am now officially waiting on the GC's sheet rock guys to finish up and I can go install this one.Here's a shot of the hidden hinge set up. The wall side bracket slips off the surround to make it easy to install. I'll make a template before installation then just line up the template with the fireplace, install the wall brackets, and hang the surround. It will "float" off the wall leaving 5/8" gap.Sprayed the whole thing flat black, then taped off the sheet metal, leaving just the bolt heads, joints and grill to get covered in satin clear to give it a little contrast. (Yeah I know newspaper is totally hack for masking, but I left the roll of masking paper at home and didn't feel like going all the way back to get it.)There it is, now I've got to find a place to set it out of the way so I don't scratch it all to h***.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Nice work Brian. I can't begin to imagine the hours involved.....Mike
Reply:Thanks Mikey.Actually it's not too bad. Fab time- 24 hoursPaint time- 8 hours, but that should have been about 4 hours but there was a blemish in the finish and I had to re-shoot one of the sheet metal panels.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Brian nice work I like your hidden hinge set up
Reply:Finally got to install this. I had to wait 1 month for the sheetrock, and paint to get done.We finished that up before lunch, then put these up after lunch.They're for a local paving/concrete/highway contractor. They found me about 2 months ago and have got bids for 3 jobs from me, so far. I have to go look at another project with them tomorrow. As long as they like the quality and inspectors ok them (they'll pass, I'm confident they're to code) we're golden with this crowd. Even finished 2 days ahead of promised schedule. And they're one of the largest in WNC, could turn out to be a very good thing sub-ing for them.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:simply gorgeous