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Drop Forge Flywheel Repair

Drop Forge Flywheel Repair

By Heritage
Drop Hammer Gantry Flywheels for Repair

Fig 1. Drop Hammer Gantry (inverted) showing X2No. Flywheels in need of repair (#1 & #2)

Drop Forge Flywheel Repair

As part of the Black Country Living Museum’s (BCLM) ambitious Forging Ahead development project an Industrial Quarter will be created to reflect the region’s rich heritage in manufacturing.

A key part of this will be the recreation of Smith Edge Tools – a Drop Forge from Roway Lane, Oldbury which was most famous for manufacturing hammers up to 28lb.

BCLM collected the Drop Forge equipment from the site when it closed in the early 2000s including the gantry and motorised mechanism, stantions, anvil bases and tups (hammers) with the aspiration that these could be installed in a working forge at the museum.

The equipment has since been stored in an external compound awaiting restoration.

Forging Ahead has created the opportunity to repurpose the equipment which has recently been recovered from the compound and reviewed to understand what repair work is necessary.

It is apparent that X2No. Flywheels on the main drive shaft are in need of repair – being cracked and in some cases missing sections of the outer rim.

The flywheels are comprised of two semi-circular sections bolted together over the main shaft.

BCLM are seeking to have the flywheels repaired in readiness for the installation of the equipment in the recreated Smith Edge Tools.

Drop Hammer Restoration
Flywheel 1 - 2 section flywheel annotation.png

Fig 2. Flywheel #1
2 section flywheel (bolted together)
< 104cm diameter >
Width (total): 14.5cm approx.
Inner rim: 12cm approx.
Rim: 1cm approx. Drive shaft measures
32cm circumference (approx.)

Flywheel damage repair

Fig 2a. Flywheel #1
DETAIL of damage

Flywheel cracked damage

Fig 2b. Flywheel #1
DETAIL of damage

Flywheel 2 - 2 section flywheel annotation

Fig 3. Flywheel #2
2 section flywheel (bolted together)
< 104cm diameter >
Width (total): 11.7cm approx.
Inner rim: 8.6cm approx.
Rim: 1.4cm approx.
Drive shaft measures 28cm circumference (approx.)

Flywheel damage

Fig 3a. Flywheel #2
DETAIL of damage

Flywheel detail of damage

Fig 3b. Flywheel #2
DETAIL of damage

New Flywheel 2 section repaired
New Flywheel 2 sections repaired
Victorian cast iron railing restoration

Restoring Victorian Cast Iron Railings

By Heritage
Victorian cast iron railing restoration

At Cast Iron Welding Services, we recently performed expert restoration on a Victorian-era handrail in Lancashire. The old Victorian handrail was located at the top of a stone canal bridge and, as well as the wear and tear making the handrail an eyesore, it was posing a health risk to members of the public enjoying the canal path.

These Victorian rails have been a part of the aesthetic of the area for over 100 years and, as a result, are an important part of the heritage of Lancashire. At Cast Iron Welding Services, we take heritage seriously. We were founded in 1947, so all of our expert welding team know a thing or two about the importance of history.

The only problem with history is that it is prone to wearing, rusting and fading away. At Cast Iron Welding Services, we have the expertise and passion for ensuring that stunning pieces of cast iron history last long into the future. Our heritage restoration services have ensured that many historic landmarks maintain their unique beauty and sense of grandeur.

Victorian cast iron railing ciws
Victorian cast iron railing repairs
Victorian cast iron railing bridge repairs

Our cast iron restoration process

We have developed our gas fusion welding process over many years of dedication. Because of that, we were confident that we could get this Victorian handrail back to its very best. When we arrived on site, the handrail looked rusted and damaged and was barely recognisable as the striking cast iron structure that it once was.

The handrail was completely broken away from the stone wall that supports it. Many of the cast iron support pillars were also broken. With this area being incredibly beautiful and appealing to walkers, joggers and cyclists, safety was just as important as appearance with this restoration job.

We took great care to work this piece of historic metal free so that no further damage was done. Once we had completely removed all the remaining rails from the stonework and gathered all the broken pieces from the footpath below, we brought them back to Coalville for the restoration work to start.

Victorian cast iron railings
Victorian cast iron railings restoration

Our expert team of engineers then painstakingly restored the damaged and rusted cast iron handrail back to its former glory. Seeing the beauty of the past emerge from the rusted wreckage of the present is always a satisfying experience. And this was no different, with sturdy and historic Victorian cast iron soon emerging from beneath the rust.

Once completely restored, we painted the iron with care and dedication. With the handrail finally looking at its best, we installed it back in its home for yet another happy client. We’re always incredibly proud of our work, but when it comes to restoring a piece of history back to its former glory, we could not be happier.

Victorian cast iron railing bridge restoration
Victorian cast iron railing

Expert cast iron repair services

So much history and heritage have been crafted from cast iron. So, at Cast Iron Welding Services, we have made it our mission to ensure this history is with us for many years to come. Throughout history cast iron has been used to create stunning ornamental pieces as well as robust structures.

Unfortunately, as these cast iron creations have been battered by time and the elements, many have worn away and become a shadow of their former selves. The same can be said for classic car parts and other vintage products made of cast iron. Our team of expert engineers has honed the process of keeping history alive to a fine art. With restorations of vintage cars, historic structures and more, we are a one-stop shop for cast iron restoration.

Over the years we’ve developed a reputation for only the best restoration work. So much so that we were recently seen on TV helping Richard Hammond restore a classic car for his new show. We have also worked with the National Trust and other organisations dedicated to keeping historic landscapes looking at their inspirational best.

If you have a vintage car or piece of classic cast iron that needs professional restoration, contact Cast Iron Welding Services today. Our dedicated team will be able to offer expert advice and quotes for any type of cast iron restoration and repair. For more information on how Cast Iron Welding Services can help you, request a brochure.

Richard Hammond uses Cast Iron Welding Services for Classic Car Restoration

Richard Hammond Visits Cast Iron Welding Services

By Classic & Vintage Cars, Heritage
Richard Hammond uses Cast Iron Welding Services for Classic Car Restoration

We’re quite used to seeing famous classic cars and vintage engines at our Cast Iron Welding Services workshop. However, we were excited to add a famous face to our guestbook when Richard Hammond visited earlier this year. One of the UK’s best-known motoring TV personalities, Hammond dropped by while filming his new show “Richard Hammond’s Workshop” for Discovery +.

Cast Iron Welding Services on Richard Hammond’s Workshop

The former Top Gear and The Grand Tour star will set off without his regular co-hosts James May and Jeremy Clarkson and open his own classic car restoration business, named The Smallest Cog. The six-part series gives viewers a look into the fascinating world of classic car restoration and follows Richard as he tries to get his new venture off the ground.

One of the first challenges met by Richard and his team was restoring a classic 70’s supercar. Hammond came to our experts at Cast Iron Welding Services when he discovered a large crack in the cast iron V8 engine block. As leaders in cast iron engine repairs, we were delighted to assist the petrolhead presenter by completing the repair work. Our expertise allowed us to help Richard get a fantastic piece of automotive history back on the road and driving better than ever.

Cast Iron Welding Services vintage and classic car restoration

Vintage and classic vehicle restoration is a rapidly growing industry. As time passes, these beautiful pieces of history suffer from wear and tear and the negative effects of ageing. At Cast Iron Welding Services we have proven ourselves to be the best cast iron welders in the business for classic car restoration. As a result, we have seen our businesses boosted by celebrity and media interest, as well as partnerships with large restoration organisations.

Our Managing Director, Peter Palmer, said: “It was pretty exciting for us really… We were also on the Yesterday channel on Monday as part of a film of the restoration of the North Bridge.”

Cast iron engine block welding experts

Our expertise in welding and repairing cracked and damaged cast-iron engine blocks, gearbox casings, cylinder heads and exhaust manifolds can vastly extend the life of your vintage vehicle. Our engineers can also repair many other classic car parts, including any damage caused by frost. With many years of industry-leading restoration experience, it is no surprise that we are being recognised by the TV world and famous faces like Richard Hammond.

History and heritage at Cast Iron Welding Services

At Cast Iron Welding Services, we have a strong affinity with Richard’s journey into the classic car restoration world. Hammond was inspired to undertake this challenge by memories of his grandfather, who became a coachbuilder after World War II and spent his life working in Birmingham and West Bromwich. Richard wants to follow in his footsteps and work with classic vehicles himself.

As a company founded by two brothers back in 1946, we felt an instant kinship with Richard’s family heritage. Over many years we have perfected our methodology for gas-fusion welding for cast-iron engine blocks, making us the perfect choice for classic vehicle restoration. With such closely linked history, it is no surprise that Hammond chose us for his restoration work, just like so many discerning classic car owners have done in the past.

Richard Hammond uses Cast Iron Welding Services for Classic Car Restoration and meets the team
Richard Hammond recommends and uses Cast Iron Welding Services for Engine Block Repairs and Restoration

Cast Iron Welding Services cast iron restoration experts

It’s not just classic cars that our cast iron welding expertise applies to. As seen on the Yesterday channel’s Great British Landmark Fixers, we also offer Heritage Restoration repairs that preserve historic cast iron architecture. In the episode, Cast Iron Welding Services joined a hand-picked team of specialists to restore Edinburgh’s historic North Bridge. Our renowned cast iron restoration process was instrumental in getting the structure back to its former glory.

Cast iron has been historically used for both structural and ornamental building purposes. However, much like with classic car components, many of these structures have fallen into disrepair and need expert restoration. This is particularly true of structures built in the Victorian era, as they have been exposed to the elements for longer. Our dedicated engineers use their expertise to keep history alive with the restoration of both classic cars and historic structures.

If your vintage car or classic cast iron structure could benefit from expert restoration, contact the Cast Iron Welding Services engineers today.

Side view of the wrought Iron fanlight restoration done at a stately home in Norfolk

Wrought Iron Fanlight Window Restoration: Tips and Insights

By Heritage

Cast Iron Welding Services are happy to update on a heritage restoration project we had been working on a few weeks ago, you may have seen we posted a while back about the Samuel Wyatt Vinery at Holkham Hall in Norfolk project.  The main contractor for the project being Messenger BCR Group.  We restored the cast iron supports and arch braces together with restoring a fanlight which is a beautiful wrought iron and lead window placement.

Holkham Hall Vinery Cast Iron Welding Restoration Project

We have just received feedback from our client to confirm the window has been put back in situ and in their words “it looks fantastic! Please pass on our thanks to the team for their hard work”

We are so pleased to have a happy client and to see the end result of our teams hard work.  We always share with the team when we receive positive feedback as it is so important for the team to see the results of their efforts.  Feedback like this makes all the difference.

Front view of the wrought Iron fanlight restoration done at a stately home in Norfolk
Side view of the wrought Iron fanlight restoration done at a stately home in Norfolk

Marie Palmer‘s Video Transcript as part of the Directors Diaries:

“Hi everyone, today we want to catch up regarding a recent project at Holkham Hall in Norfolk we did for the Samuel Wyatt Vinery. We repaired some cast irons supports and also sorted the fanlight window placement that sits at the top of the building. It’s actually now being put back into situ, the client has sent us finished result photographs as they’re so happy. It’s fantastic to hear the positive customer feedback. It’s not a common repair, it’s very unique and a rare, delicate request – the finished result looks amazing and it’s nice that we’ve got a very happy client again. “