A prototype for a larger piece. Turned out better than I hoped and worth sharing. The idea is to replicate the style of a gothic stained glass window using nothing but metal instead.
Around 10 inches tall. It was fiddly and time-consuming to create the arch. The depth and free space inside gives it an extra dimension. I will go through the materials I used and what I did to create the necessary shapes.
Let's begin with what the main structure is and what we did to shape it. I began with one of the drawers I had from a falling-to-bits cantilever toolbox. It was cut in half lengthways leaving effectively one end open. To form the arch I had to create a slit down the sides so I could then fold the flaps of metal inwards to meet in the middle. I didn't force it and it created a great arch shape naturally. This was then tack welded at the top to keep that arch in place. It was tricky as I welded down the rear of the arch to attach it to the back of the window. The metal is really thin and even the welder on the minimum setting was punching holes through. It was time for my patience to kick in. Weld a tiny amount, let it cool for a few seconds then repeat over and over. Once this was done on both sides it was strong but didn't look very pleasing. I have a box of thin and long mild steel nails that were shaped and then welded over the top of the first welds. I then did a similar thing to the front of the arch to make the frame a bit more chunky.
Now that the arch is in place and sturdy, I could start adding the window details. I went back to the box of nails for the two lower arches. I wanted to space these for lots of air and light to be able to get in. The rusty back was something I didn't want to hide. I shaped the pieces for these and got them into place. Welding them into place is where the small size of this was awkward but we got them in!
For the upper details, I found a hole saw that fitted the bill perfectly and sat in the space I had left above. I wanted a concentric circle as a detail within the hole saw. I cut down a ring spanner for that job. It's quite strange as the part of the handle of the spanner used to position the ring disappears when you're looking at the front, giving the impression of a floating ring.
The blue paint showing years of wear and a flash of colour that really shows in the sunlight. It's a nice nod to the stunning colours of stained glass windows.
For the base I had left over a piece of plasma cut steel that has a rough edge. It was the perfect width and was meant to be there from day one! I wanted it to look like an old stone lintel on a church building or similar.