Metal fence design follows the same principles used in any other art. Similar curves, angles and shapes are more pleasing to the eye, even if the individual hand-crafted sections of the fence vary. Contours, lines and shapes can take a boring vertical fence with simple rectangular sections and transform it into an eye-popping conversation piece that will add value to a property for years. Does this Spark an idea?
Rough Sketch
Make several sketches of the proposed fence and have the owner choose a design. Metal fences can be straight or curved, scrolled or plain. Victorian designs tend to be very ornate, with flowing curves and nature elements such as leaves, fruits and vines. Modern fences are more utilitarian, with uniform, straight sections.
Wrought iron is the most durable metal for designing fences, and adds the most value per dollar spent. Although aluminum is light and easy to bend, it costs twice as much as or more than wrought iron. According to Robert Butler, lifetime handyman, independent contractor and former US Navy machinist on the USS Sacramento, America and Shangri-La, "Aluminum lacks the strength to withstand wind, snow or other abuse, and loses value rapidly within a year or so of installation. Stainless steel can cost nearly three times as much as wrought iron. Stainless steel is stronger than wrought iron, but much harder to bend and hammer to shape" (Reference 3).
Engineering Considerations
Obtain a utility company map of any buried gas, electric or water lines anywhere you intend to dig. Survey and measure the area you are fencing for grades, measurements, corner angles and obstructions. Engineer around grades.
Apply for a building permit and inquire whether or not you need a zoning permit as well. According to Robert Butler, "Even to put up a shed with a skid foundation in some cities, you have to get a building permit" (Reference 3).
Obstacles such as trees, shrubs and boulders need to be removed. Depending on the owner's wishes, small rises and lumps in the ground may be flattened using a small tractor with a dozer or box blade. The ground will have to be re-seeded. This is usually easier than trying to engineer the fence around the irregularities.
Stake out the perimeter with wood survey stakes and drive a digging bar or piece of re-bar into the ground where fence posts will go to ensure there are no rocks, roots or other unseen obstructions. If possible, build all your fence sections in your shop and bring them to the job site ready to install.
Triple-Check Everything
Check all work on the structure a minimum of three times before showing the finished product to the buyer. Nothing dims an owner's view of your artisanship as much as simple mistakes. A missing bolt makes a rickety fence. A section of work that has not had the weatherproof finish applied do the fence section rusts after the first rain. Once you have checked for problems and shown the owner your work, deposit your check immediately upon leaving the job site.
Design Tools
With everything from AutoCAD to CorelDraw available, design is no longer the time sink that it used to be. If your design will require a lot of scroll work, though, make a full-scale drawing before cutting and forging your parts. Heat your wrought iron, bend it to shape, and compare it to the drawing. Aluminum would usually be bent cold. There is no real need for calipers or other precision tools unless your design requires every section to be uniform.
Principles of Design
According to mixed-media artist John Lovett, principles of design "are the building blocks used to create a work of art" (Reference 1). Metal fence design uses at least four of the seven principles of design that Lovett finds essential: line, shape, direction and size. Make each section the same scale, using similar curves and angles.
Anyone can design a board-straight vertical fence using a plumb bob and a spirit level. It takes skill to create a curved fence with individually designed sections without it resembling an exploded ironworks factory. The true mark of handcrafted work is the slight differences in each piece.
Repetition of design elements also creates visual impact. Even free-form curves made to resemble willow withes or vines should repeat throughout the fence. Geometric shapes add a formal flair, while free-form natural shapes leave your visitors feeling like they have stepped into fairyland.
Expert Insight: Essentials
According to 20-year veteran industrial and artisan blacksmith, Gypsy Wilburn, "Learning to weld is an essential design skill. You should have a minimum of a semester of welding instruction or similar experience before attempting to design a wrought iron fence. I suggest that you buy a 110-volt gasless MIG welder. Most serious welders use Lincoln or Miller brands, as off brands tend to be underpowered or burn out the transformer or handpiece by overheating during anything more than light use. "
"Nobody taught me to weld. I was working in a machine shop. They needed some parts welded and asked if I knew how. I said yes, and they stuck me in the basement with a cart full of parts and a WWII vintage monster of a welder. I used scrap that was laying around to figure it out, and by the time I was done with the parts I had a pretty good handle on stick welding" (Reference 2).
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