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Home Expert Carisha Makes A Hubbardton Forge Chandelier

Home Expert Carisha Makes A Hubbardton Forge Chandelier

– [Carisha] Today we’re
here in Castleton, Vermont, visiting Hubbarton Forge
land modern blacksmiths. Wait, here we go, hi! We’re here today to make
the Dahlia Chandelier. It’s a pretty awesome
process, so let’s go ahead and get started. We’re going to do this start to finish. This part is the first
part of his process. This metal comes in, it’s
already cut like this. And they have to forge it which is using these hot ovens, and then
using the air compressor to create that stamp. It is a process, it’s
definitely dangerous. You have to be dressed like this, this is, you know, it is what it is. (laughs loudly) – Hold that, just flip that,
and you’re ready to go. – So just flip it over.
– Yup. – You make it seem so easy. For some reason, I feel like
it’s not going to be for me. But we’re gonna see what happens. (laughs) Ahh!
(laughs) Why they’re trusting me
with this, I have no idea. Yeah, stay back.
(laughs loudly) Everybody stay back. (machine bangs) (machine bangs)
Success! I did it right, right?
(laughs) Nobody got hurt in the
filming of this program. And then, we go from
here to the next step. (upbeat music) So right now we’re in the hot bend area. What’s going to happen is literally that we’re gonna bend steel. So, he just took one of these pieces that’s part of the Dahlia chandelier, and he put it into, what
really looks like a pizza oven. He didn’t stick his hands in, because he wouldn’t do that
in a pizza oven either. He used a little tool, almost like tongs, to stick it in there and
because of the length, the whole thing can go in
there at the same time. So now you can see
they’re like, burning hot. He’s going to weigh this down, hammer it into place, protecting his hands the whole way. Basically when it turns
gray, it’s ready to go, it’s already formed,
and the next step will be, I think getting off some
of what they call the skin. But right now we’re goin to step away because he said it takes 30 seconds, I don’t want to accidentally touch it. I don’t want my gloves smoke, I don’t want any part of me smoking. (laughs loudly)
The only thing I liked smoked are ribs. – We have a P and T department, so it’s a Prototype and Tooling. They make tools for each and
every fixture that we make. – [Carisha] So this was created
for you, for this particular Dahlia Chandelier.
– [Man] Yes, correct. – Metal basically has a memory, so if he didn’t use the
clamp, and he just kind of folds it into form, it
wouldn’t hold its shape, it would kind of start to
go into a different way as it shrunk, so that’s why we wait on it to actually turn completely
gray before they move it to the cooling rack. These are going to go into
these machines over here, and all of this kind of like, flaky skin, is gonna come off, and it’s
gonna be shiny like this. And the bottom line is, that at the end, a lot of people like to see the texture. They call this the substrate, for our purposes, let’s
just say it’s the way you can see the veining in wood, it’s the same way they want you to see the veining in this material. So this is fayonite. Fayonite is the thing
that’s in the machine, that’s gonna essentially get the skin off of that metal piece
that we just put in. It takes about 45 seconds
for it to go through the whole cycle, spinning around, and then about 30 seconds
for it to stop and settle, and then we can pull it out. That’s really good looking. We just left the tumbling room, all the materials have to
feel the same kind of texture, at first it was a ceramic nivea, and there it removes all the shine so it’s a little bit of a patina, a little bit of an aged look. And then it goes into
where, essentially corn cobs have been ground down, and
that’s the drying process. It all happens in there,
and it probably takes a whole ten minutes to get
the look that they want. And it’s also very loud,
so that’s why I’m doing this in here, and not in there. (upbeat music) We’re going to see some
molding, more fire. And they told me I’m
not allowed to do this. Why not?
(laughs) So these are the long pieces that we we first created that was step one. Bent and forged in that other space. Every one of these processes has a clamp to make sure it’s perfectly
where it needs to be. – [Tom] Yeah, yeah. – Is this like on a lazy Susan? – [Tom] Yes. – This is a lazy Susan,
but no food attached. – [Tom] It makes it a lot easier. It does make it a lot easier. So, I was coming in here thinking that he was going to be using
flames to make this happen, but it’s actually electricity, which is why he’s got the
fancy head gear on, hi! And that allows him to look out
and look at what he’s doing, which is why I’m going
to have to get some fancy equipment on too. Whoa. This is so crazy, when you have this on, you can clearly see
everything that’s happening, but as soon as that
electric volt goes in there, it all goes back, and
all you see is the light. And that’s your way of knowing that you hit the right
spot, and that’s when you’re doing the welding with your little, what is this, is this copper? – [Tom] It’s copper on the outside. – [Carisha] Copper on the outside? – [Tom] The inside of it is steel. – I can understand now why I wasn’t allowed to do this. (laughs loudly) – It’s a lot of fun. – They’re not gonna let me take this home, but it’s pretty fabulous
and I wish they would. I don’t even know how much it costs yet. (laughs loudly) Now all the welding is done, and these are the two pieces that are going to form the Dahlia. The next steps are that
we’re gonna wash this, and then we’re gonna go put
on the powder-coated finish, and then it will essentially be complete. In this little bin here,
it’s not so little, is the Dahlia pendant. But there’s other things in here too, the way they batch these together is by how they’re gonna be finished. So this is all going to be
one of their golden finishes, all of those pieces will
be in here, go in there, and then go into the final room to get that powder-coated finish. Bottom line here, there is a
lot of science is happening in this machine behind us, and all four of the bathing
processes that take place are all meant to get it
to the final process, where that powder-coated
finish is going to be able to hold onto it, and then be ready to send to your home. – [Man] Once it’s washed,
it goes into a drying oven, so that’s 17 minutes at 350 degrees. – [Carisha] Oh, so it’s
really oven temperature? – [Man] That’s correct. So the residual liquid
that’s left gets dissipated. – [Carisha] Okay. (upbeat music) – This room is temperature controlled, there’s not too much humidity, and this is where the powder
coating actually happens. It’s gotta be a controlled environment, so they call this the environmental room. So this is what we’ve been
working on all day today, and now it’s ready to finally
be part of this process of finishing, you’re fast. – Gotta learn fast. – So these are, what
you’re putting on right now is gonna protect it from
the paint finish, right? – Yeah. – [Carisha] So are you gonna actually do your twisting on later? – Yeah
– [Carisha] Yeah, okay. – It helps for the
assembly department so what they’re building and
putting wires and stuff. – Right, I’m all up in your space. – It’s okay. – All of these things are
gonna be put on the line here, all together but far
enough apart so that when they’re moved in there,
they can be painted properly and nothing will be touching each other, ’cause that’s not what you want to happen. I just got to the powder coating room, where they’re gonna let me do it. The cool thing in here is
that it’s kind of like echo-y because all of the paint
needs to adhere that way, not onto me. They have 26 different finishes, so I don’t know which one
we’re gonna go with today, for the Dahlia, but I’ll
find out in a second. – The powder coating is electrostatic. So the powder is being
charged, and then sticking to the steel. – Yeah, okay. – So basically we’re
standing on a metal plate, you’re grounded, I’m grounded. – Oh.
– The line is a negative charge, the gun is
creating a positive charge. Negative, positive, coming in together, therefore sticking to the material. – Yeah, okay.
– Okay? This is actually bronze powder, – So this is going to, it
looks brown or kind of taupe-y but it’s ultimately gonna be
bronze when it’s finished. – Yes, it’s actually gonna be a, – It’s bubbling, what’s that about? – So, that’s considered what we call a fluidized copper. So there’s a diaphragm
of air on the bottom. – Nobody knows what that
means in the world, he does. – So, basically what it
is, is a plate but millions of little holes. – Okay, that’s easier. – And the air is thinning out the powder. – Okay. – You wanna go like this
and just kind of work your way on each one. (laughs) – Is this good? – Try to give it a little spin. – Oops, too fast. (upbeat music) Tada! So now it’s gonna go on a gun,
or like a dry cleaning wheel, over to bake in an oven at 400 degrees. – Ironically, here’s a Dahlia right here. – Oh, there ya go! But this is not the one we did, but this is a black
opaque finish that’s going down the line right now, and are we in the, this
isn’t the warm part though yet right? – No, this is the cooling tunnel. – This is the cooling tunnel we’re in. – Everything is unloaded. – Right here. – Yup, right here.
– Okay. – It will go to a quality inspector, which is inspecting
all the powder coating, making sure the right color is there, and then it will go over to assembly to get kitted for all the components. – [Carisha] Oh, awesome. – All the stock kits over
here have been kitted. – Okay. – All of the labels, all of
the customer instructions, so it’s a step by step
instruction for the customer what they need to hang it. – [Carisha] This is gonna
get my address on it, right? – [Woman] Oh yeah, there ya go. – Right.
– Ship it how it goes wakes up the time line. – [Woman] The Dahlia ship’s broken down, so it ships in actually
two separate boxes, but inside a master pack. – Okay. – So it’s the way of keeping
it the safest we can. – Right. – But in this case, we’re trying to secure the fixture from movement. – Oh, are these the hard foamy things that you’ll get in certain packages. – Some of them are hard, but this one actually creates a
customized pillow around anything you want it to. – Is it blowing up right now? – Yeah. – Oh, wow. – Yup. – Oh and it’s warm. – Yeah, it’s warm, about 140 degrees. – So you have to move really fast. I feel like it’s a relay race. – Yup, it’s very fast. – And put it underneath the plastic. – Yup, just put it underneath there. – Is that good? – That’s perfect. – Okay. – Just let her set up. – It’s like an experiment,
that is so gnarly. So this truck is always here. They fill it up throughout the day. When it’s full at the end of the day, UPS comes and picks it up. Next stop, it’s at your door. You have been awesome. – Thank you so much. – So, like, you know so much, okay. (laughs) That was awesome. Now we’re gonna go see some
finished product in the front. There are a lot of
people involved in making every single light fixture here, and Hubbarton Forge. And the Dahlia is no exception. At over two feet in diameter, every single piece is touched by skilled artisan to master
every element of their work. So at around $1790, I
believe it’s worth it. Tada!
(upbeat music)

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