To make an ironwork Christmas tree, you can either forge a tree from flat bars or square stock, or weld one using materials like rebar or horseshoes. The basic process involves designing the tree's shape, preparing and shaping the metal (forging, bending, or grinding), cutting and assembling the pieces, and then finishing the piece with paint or another treatment.
Method 1: Welding with rebar or horseshoes
Gather supplies: You will need rebar or horseshoes, a welding machine, clamps, and a grinder.
Plan and position: Lay out the pieces to form your tree's shape on a flat surface. You can draw the design directly onto the metal with chalk.
Weld the base and trunk: Weld the base pieces together to create a stable stand. Then, weld a vertical trunk to the base.
Weld the branches: Tack-weld the horseshoes or rebar pieces to the trunk, staggering them to create the tree's layers.
Finish and refine: After the welding is complete, use a grinder to smooth out any rough edges or imperfections.
Paint: Once the tree is cooled, paint it to your desired color, such as green, or a different finish.
Method 2: Forging a tree from flat or square stock
Plan and prepare: Decide on your tree's design and gather your metal stock, such as flat bars or square stock. You can sketch your design to guide you.
Create the branches: Heat and hammer the metal to forge the branches. For instance, you can forge a point on the end, bevel the edges, and then use a chisel to add texture or detail.
Cut the pieces: Mark where you want to cut the branches. You can use a chisel and a hacksaw to make clean cuts.
Forge the stump: Create the stump, ensuring there is a good transition from the base of the tree to the stump.
Assemble and weld: Weld the forged branches to the stump, ensuring they are securely attached.
Finish and refine: Use tools like a grinder to clean up the welds and a chisel or fuller to add more texture and detail if needed.
Paint: Paint the completed tree in your desired color and allow it to dry.