Fig. 3. Cutting Tool.
Fig. 4. Modeling Hammer.
In [Figure 1] is shown a leaf made from Number 16 sheet steel and [Figure 2] shows a pattern of the same leaf. In making a leaf of this kind, a full-size drawing is made just as it should look when modeled. From this drawing a pattern is developed as the leaf would look when in the flat. It is impossible to lay it out accurately. The method used is to find the stretch out of the leaf by measuring along its greatest length. This can be done by using a pair of dividers. The length found is then laid off on the metal. The widest parts of the leaf are then measured and laid on the metal. Having the length and width, the rest can be sketched in. The leaf is now cut out with a narrow cold chisel that can be made to follow the curved line. This cutting should be done while the metal is cold. The leaf shown in the illustration has been fluted with a steel hand-tool. In doing this a tool as shown in [Figure 3] is used. This tool is made smooth, rounded at the base like an ordinary fuller and then hardened. The fluting is also done while the metal is cold. Lines are marked on the metal with a slate pencil and then sunken with the tool and hammer. In modeling the leaf a hammer like the one shown in [Figure 4] is used. It is called the modeling hammer. This hammer has a ball on one end and a pein on the other, both of which are made very smooth and without sharp corners. These hammers are made in various sizes. In modelling the leaf it is heated and hammered on the back side with the ball of the hammer, using the elm block to hammer on. The ends of the lobes are then formed to give the whole a decorative effect. These leaves are generally used in grille work and are welded into position. In [Figure 5] is shown part of a grille with a similar leaf welded on. In welding leaves to the members of grille work the bottom part of the leaf is formed around the bar; caught with a pair of tongs, it is heated, using a flux when hot. It is then taken to the anvil and welded. A small collar is finally welded in front of the leaf as shown in the illustration.
Fig. 5. Grille with Leaf.
The leaves shown in the illustrations are made to cover the grille on but one side. If a grille is to be seen from both sides when in place, the leaves are cut out symmetrically and then bent and modeled to fit over the top and sides of the bars so that they appear finished from both sides. [Figure 6] shows the pattern of such a leaf.
Fig. 6. Pattern of Leaf.