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Old 11-22-2012, 09:14 AM
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Default Forged door lever sets

Here are some door lever sets that I made for a customers house in Tahoe. I tried to do somewhat of a pictorial showing how I made them. Each piece was made an average of 3 times before I hit upon the right length, diameter, amount of taper, etc. These were made to match a sample handle that was given to me.
The first picture is a picture of the back plate, which was under discussion i another thread, which has a spring mechanism in it to return the lever to center.To make these I made a punch and die for my ironworker. It is a piece of 1/2" plate with a 2" hole cut into it, then the edge of the hole as eased and faired out a bit. The punch was a piece of 1 3/4 cold rolled round that I tapered the end at a little less than 45* then rounded the edges a wee bit. I also made a top plate to clamp it down to help avoid warping the back plate with punching the dimple in. These were done hot, as they tended to warp and tear when cold.
The next picture is the blank I used to make the handles. It is about 6 3/4 long with 1" of the end turned down to 1/2" and the center bored in about 1/2" with a 5/16 hole.
Then they went into the forge and were hammered into square for about 1 1/2", then into octagon, which made that section about 4" long and 3/8 diameter.
I then tapered them down, and used a cross peen to flare the ends out.
Then I put the flared end into a swage that I made by pounding a ball peen into a piece of 1/2 plate (hot of course) until I had the depression shaped how I wanted it.
I then curled the handle around a form (1 1/2" pipe). Then after that was done I put the handles in the vise (smooth tooth blacksmith vise) and heated a small section with a torch and made the 90* bend in the handle. (the pic of this doesn't show the machined portion on the back, as this was one of the first trials, before I knew the right length)
I then painted them, installed a nylon bushing, assembled the handle, the spring mechanism, and tig welded the parts on the back side and quenched before it could heat up the paint.
Then I simply repeated 12 times.
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Old 11-22-2012, 09:16 AM
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The rest of the pics
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Old 11-22-2012, 09:25 AM
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Walker you make this stuff sound so easy! Very nice work, I'm sure the customer is happy.

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Old 11-22-2012, 10:29 AM
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Really nice looking set of door handles,exactly what I would expect to see from the craftsman we all know you to be.
I would love to be able to do something like that, but I doubt I would have the patience to fabricate one, never mind eleven more.
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Old 11-23-2012, 04:47 PM
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Fine work!
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Old 11-23-2012, 05:49 PM
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I like those a lot. I have 2 sets to make here as I can't find any used ones that will work and new look awful.
I think I am going to shamelessly steal some of your production methods.
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Old 11-23-2012, 07:56 PM
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Help yourself. If you have any questions give me a shout.
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Old 11-23-2012, 08:59 PM
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Hi did you use a form/die/jig for the bending or all done free hand?

Nice work..
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