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  1. #1
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default OK So I Want To Make One Of These

    Just to start off - I already know I am mad. So, now that we have that out of the way ....

    Ideally, I want to make a two and a half bowl "Farmhouse" (or butler's, Belfast, apron) sink.

    I have been thinking about this a lot lately, as work will be commencing on our own kitchen in the next 6 months and I will be adding a range of unique design elements into it, like this one.

    Here are a few ideas:
    -- I can get a 2.5 bowl stainless sink and plate it in copper, to use as the "bowls"
    -- I can get single bowl sinks in the right dimensions (Stainless) and plate those.

    By the way, the reason I am thinking of doing it this way is cost - copper is exxie and apparently, creating the radii in the sink bottoms is very difficult. Stainless sinks, especially used ones are cheap - my platers are too and good) .... and they will plate the bowls 8 or 10 times to ensure they're well finished.

    OK so I need to make/get made the top surrounding section. Importantly, I do NOT want it to look pristine. All of the marks (though still done neatly) of being handmade; a little silver solder here and there, rivets and hammered folds will be great. The key to all this is how it will fit onto/into the factory made bowls.

    Also, I don't think it needs to have such sharp edges as the ones pictured .... I am thinking I could make an MDF former/template and rout a radiused edge all round then form the copper over it to get the shape.

    Anyway, that's my totally wacky idea and if anyone can assist with its manufacture or ideas I'd be most grateful. I know it's a considerable challenge but the combination of minds and hands can do almost anything and this seems like it would really be fun and a nice way to showcase this area of our kitchen.
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  2. #2
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default

    Just thought I'd show what they look like in place - obviously some of these are not copper, but you get the idea.
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  3. #3
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    I believe one could be fabbed from 2mm sheet.Ideally at a sheetetal works ,forming the tubs from 6 separate pieces precision formed in the brake press,

    ie

    • the main section( inner) front, base and rear as one folded panel
    • left end, centre and right end vertical panels
    • the front outer panel


    The panels can easily be brazed by a sheetmetal worker, brazing being easier to perform on the interior fillet corners than arc .Less dressing is required as well.Black steel will take very well to brazing. Set the corner fillet joint up correctly and it will radius beatifully.

    This in itself will cost unless you are a skilled sheetie.
    I can see a days labour in there ,to mark out cut, form, assemble a, tack , braze and dress. That would put it in easily in excess of $500 before plating.

    Grahame

  4. #4
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default

    thanks for the response - are you referring to just the outside? If so I intend to make it from copper.

    I am no sheet metal worker by any stretch! I have made a thumblatch door handle and a couple of copper lanterns and that's it. My experience is with wood.

    Having said that, I am willing to pay for the work without question - I just need to ensure I get the result and as I have found in the past, one person's idea of "OK" can be another's idea of crap. I will post a pic in a minute to illustrate what I mean ....
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  5. #5
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default

    OK - believe it or not, a client of mine paid for this kitchen .... and paid handsomely. The client imports very expensive tapware and kitchen items and distributes them all over Australia .... he regularly hosts international suppliers in his home, with this kitchen!!! - when he asked me what I thought of the work done, it was all I could do to keep my coffee down!

    Not one door fitted correctly - there were gaps everywhere. Enormous pot drawers had under-rated runners and single small knobs. Base plinths were just sitting there and the caulk! It was everywhere and cracking! Don't even get me started (too late!0 on the granite benchtop .... the stuff on the sink cabinet was in three pieces!

    The thing was a disgrace.

    Anyway, I reworked almost the entire kitchen and produced something he and his wife could enjoy that was warm and welcoming to all who used it. (BTW the Gothic styled sink cabinet two posts up is what I replaced theirs with)

    I hope this gives fair illustration of what I was meaning in my last post about the different standards people apply/accept.... years ago I had a so-called professional automotive trimmer cover a console I had made for my car .... the thing looked like it should be in Fred Flintstone's car! I ended up ripping all the leather off it and re-doing it myself. I figured to pay the pro to do it right and get on with my life .... I still paid him but the thing was horrendous.

    In the case of the sink, I will provide extensive details and a technical drawing with nominal dimensions etc. and will be more than happy to pay for the person's time and skills. We'll see where it goes!
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  6. #6
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default

    This is the thumblatch and finger plates I made .... was a lot of fun bashing the proverbial out of some old copper pipe etc. I'm reasonably happy with the result, but if I ever do another one it will be a better .... the big challenge here (apart from no metal working skill) was that when I made this entrance, I made the door stiles very narrow because I wanted them to have the "Queenslander" look, so all the metalwork had to be finer to suit them. It all still looks OK and feels nice when used .... I just think it the main handle is a bit narrow.

    But hey, I found a use for the chunk of railway line I bought at the Trash N Treasure .... knew it would come in handy one day!

    BASH BASH BASH!
    Attached Images Attached Images
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  7. #7
    Join Date
    Oct 2010
    Location
    Newcastle Australia
    Age
    66
    Posts
    122

    Default

    I like your work and it's very original. For sheet metal fabrication I think
    hotrodders and custom car guys are the best when looking for ways to do things.
    On one of these threads here, a guy has made body parts the same way as you had suggested.
    Ozrodders.com • View forum - Construction

  8. #8
    Join Date
    Aug 2007
    Location
    Saskatoon, Saskatchewan, Canada
    Posts
    292

    Talking Yup! You're a whack job.

    If you think it will be better and cheaper to plate stainless then I would suggest instead of attaching the 3 bowels to the copper surround after, as I understand your intentions. Get them welded to a stainless surround first by someone good with tig and then plate the entire thing. Or if you can get the sink made of stainless sheet and welded together, have that plated.

    In the end though I think going with copper sheet from the start might be the best in the long run.

    Pete

  9. #9
    Join Date
    Oct 2007
    Location
    Alexandra Vic
    Age
    69
    Posts
    654

    Default

    I am not as up on plating as I used to be, but it was my understanding that stainless did not plate well.

    Platers often use copper as a base plate layer to built some thickness in material that is hard to polish well, because it is soft and easy to polish back for a smooth foundation for chrome etc.

    If you fab the unit from an alternative metal and copper plate it(even a number of times) you will end up with a thin layer of copper deposited, and copper being soft you would likely wear through the copper in places exposing the base metal within a couple of years of normal household use.

  10. #10
    Join Date
    Jan 2004
    Location
    Kilmore, near Melbourne, Australia
    Age
    66
    Posts
    15

    Default

    No, stainless plates fine ... it also polishes up a treat, but you're dead right that the copper plating will wear away over time - this is no issue for me as it adds to the overall appeal of the sink .... at least where the bowls are concerned. I have had a sink plated in copper, which has been left in the weather for more than 5 yrs now - it has no visible deterioration except that the copper has gone brown, which was my aim. Initially I had this one done to use as a secondary kitchen washup sink on an island bench. I may still use it but I have several small fireclay sinks here that are very nice - see attached. The main issue with plating the bowls is their depth as it relates to how electroplating is achieved. An anode has to be fashioned that ensures the plating is effective. I imagine several anodes may have to be used and this will be a trial and error type of thing, but my platers are great people and I am yet to give them a job they couldn't do.

    The main reason I am considering the mass produced stainless bowls (and plating them) is cost and because I was told that radiused corners would be very difficult and expensive to achieve.

    by the way, at this stage I intend to spray foam into all the underside for insulation, strength and sound.
    Steve
    Kilmore (Melbourne-ish)
    Australia

    ....catchy phrase here

  11. #11
    Join Date
    Jul 2010
    Location
    Melbourne
    Posts
    9,088

    Default

    Straight large radius bends aren't that hard to do. I'd assume they are easier in copper than stainless. Although I've never fusion welded copper.
    Even if I currently had all the tools needed I'd still go with plated S/S, maybe I'm just lazy

    Stuart

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