Over time many common designs have evolved. Some designs have turned out to be more popular than others. The urn style is among these. The ornaments and patterns have changed but the basic shape has remained.

Sand casting is a form of art that is enjoyable as well as challenging. Numerous steps are involved in the process. Each step must be carried out properly or the completed piece will not be up to expectations and [...]]]> Our facility uses sand casting processes to produce brass door knockers and other decorative hardware items.

Sand casting is a form of art that is enjoyable as well as challenging. Numerous steps are involved in the process. Each step must be carried out properly or the completed piece will not be up to expectations and may need to be scrapped.

The process involves heating  metal beyond its melting point bringing it to a liquid form. The molten metal is then poured into a green sand mold which forms it into its new shape. When the metal solidifies the sand mold is broken away leaving the metal casting behind.

Green sand consists of a mixture of sand, clay and water. This sand mixture is packed firmly into a box containing a pattern of the part to be produced. This box known as a flask is made in two halves. It is designed to be taken apart after the sand is packed in it.

The pattern of the part to be made is situated at the center of the flask where the two halves come together. After the sand is packed the two halves of the flask are separated and the pattern removed. This leaves a cavity in the sand the shape of the part to be produced. With the mold cavity formed hand tools are used to cut sprues and gates into the mold. This is the pathway that the molten metal follows through the mold and into the cavity.

When the cavity, gates and sprues are completed the two halves of the mold are put back together and the mold is complete. The completed mold is then taken to the pouring area. In daily practice we prepare as many molds as the crucible can hold brass for. The molds are lined up in the casting area to await the pouring.

Now with our molds all set we will need to melt some brass. In our facility we work with a propane gas fired furnace and fire clay crucibles. We fill the crucible with pieces of brass and place it into the furnace. When the temperature gets around 1600 degrees farenheit it begins to melt. Around 1650 degrees it is liquid. When the brass is roughly 1680 degrees the dross is skimmed from the top of the crucible and some flux added. When the brass is over 1700 degrees it is ready to pour.

Cautiously we lift the crucible filled with glowing red molten brass from the furnace. Carrying it to the mold we line up our pour. Tipping the crucible the brass flows out and down the sprue, into the gate and ultimately into the mold cavity filling it completely.

At this point everything is left to cool. We clean up our mess and take a short breather. When the castings have had enough time to cool enough to solidify it is time to remove them from the mold. The sand is broken away leaving the new casting exposed.

When castings come out of the mold they have a rough surface. Sprues and gates are still attached. Additional work must be performed to convert this casting into a finished product. This typically involves cutting, sanding, buffing and machining.

This process must be repeated for every component used to make the door knocker assembly. Most door knockers consist of two castings, a body and a clapper.

When product is assembled and  complete, a solid brass door knocker like this must be protected by a clear lacquer or similar substance to prevent the surface from tarnishing and deteriorating. The clear coating will keep the door knocker looking good  for many years to come.

When I was going to High School in northern Ohio I remember the steel mills, machine shops and rubber factories that filled the area. I was greatly saddened during a recent drive past some of the old mills. A few buildings [...]]]> “American made” I am old enough to remember when America was an industrialized nation.

When I was going to High School in northern Ohio I remember the steel mills, machine shops and rubber factories that filled the area. I was greatly saddened during a recent drive past some of the old mills. A few buildings are still partially standing, some with trees growing through their roofs. This is the legacy of the rust belt, the legacy of America.

Made in America is not just a sign of quality and craftsmanship, it is a way of life. It is the fulfillment of the American dream. American made means jobs, pride, self esteem as well as a strong economy.

America’s industrial base was once the envy of the world. During World War II our industrial base won the war by out producing the entire rest of the world. Tanks, Jeeps and Liberty Ships rolled out off our assembly lines at record paces.

The following decades manufacturing was strong. Our predecessors worked hard and created a wonderful way of life that most of us living today can only remember. They lived it because they earned it.

Why did America get out of the manufacturing business?

The answer to this question can be found in our nations capital within the walls of our congress. This question must be directed to those who are responsible. Those who regulated America out of business with free trade agreements and legislature designed to cripple our manufacturing base. Those who would rather fund multiple unnecessary wars than fund clean air packages for American foundries that employ Americans. Those who sold out to the highest bidding lobbyist with no regard for the working American people.

Is it really cheaper or worth it to send our work to other countries? The answer is a resounding no, not by a long shot. Our working force and our manufacturing base is what built our country. It will take hard working Americans to reclaim it. America was built by entrepreneurs who took the initiative to follow their own path. This is how America was built and will be rebuilt, one idea at a time. The entrepreneurial spirit is strong in America. The spark is provided by necessity and need.

I have always felt that the pendulum swings both ways. Times get good and times get bad. I remember talking with my grandfather and father about the great depression. They lived through it. They also lived through World War II. They knew bad times. They also knew better times in the 50′s and 60′s. They got to the better times because every day Americans picked themselves up worked hard, and got this country going again.

Our pendulum is about to start an upward swing. It will be carried upward by the very Americans who have been sold out by the politicians. It will begin with garage shops and grow into full bloom industrialization. It will take guts and fortitude, but that is also the makeup of an American entrepreneur.

One dollar may not seem like a lot compared to our current national debt. But every dollar spent on products made in America is one less dollar that is spent empowering other countries. It is a dollar spent employing an American. The challenge now is to keep more dollars here. To get Made in America our way of life again we must work hard and and earn it one dollar at a time. We must stand up to the self serving politicians who have no regard for the American dream. America built by Americans, this is my dream. It will probably take longer than the years I have left, but I am confident that it will happen.

Made in America means more than where a product is manufactured. It represents our American way of life. The spirit of Americans will prevail.

The name  “Oil Rubbed Bronze” is also the best description for this finish.  Originally bronze items were preserved by rubbing them with different types of oil.  [...]]]> One of the more popular yet misunderstood finishes for door hardware is oil rubbed bronze. In recent years it has gained in popularity for interior and exterior home hardware.

The name  “Oil Rubbed Bronze” is also the best description for this finish.  Originally bronze items were preserved by rubbing them with different types of oil.  As the metal oxidized it darkened to varying shades of dark brown and gray. As the item is used some of the oil and dark oxidation is rubbed off leaving the base metal below exposed. The exposed areas are usually the raised areas of the item. After the item is used for a period of time it  needs to be re-oiled to maintain the finish.

Since a true oil rubbed bronze finish is constantly changing with use, it is known as a living finish. With use it will show base metal and when idle for a period of time it will again darken.

In modern times a true oil rubbed bronze is not very practical. It requires to much maintenance for most people. Even still the effect is quite attractive and is highly sought after for home decoration items.

Many manufacturers are now creating a finish resembling oil rubbed bronze but without the downfalls of the original finish. They are known as “Aged Bronze”, “Dark Bronze”, “Venetian Bronze” and a host of other names. These are manufactured using modern methods of electroplating, usually a copper color, and oxidation over the base metal. These items are then  lacquered to preserve the finish leaving little maintenance to be performed for many years to come.

Each manufacturer has their own interpretation of what their version of the finish looks like.  Products purchased from different manufacturers may not match exactly even though they are all called oil rubbed bronze or an oil rubbed bronze lookalike. There are no set standards for oil rubbed bronze.

Designed by our engraver to look great on your door with engraving or without.

Beautifully hand crafted patterns are cast into brass in our Augerburg Foundry.

Castings are engraved and finished in our studio to order.

The [...]]]> YDK71 Solid Brass Door Knocker by Your-Door-Knocker

Designed by our engraver to look great on your door with engraving or without.

Beautifully hand crafted patterns are cast into brass in our Augerburg Foundry.

Castings are engraved and finished in our studio to order.

The YDK71 has 2 large versatile areas to hold your custom engraving requirements.

6-3/4″ high x 3-3/4″ wide x 1″ thick the bolt centers for the through the door mount are 4-3/8″

The YDK71 is available with your choice of through the door mount or surface mount.

Available in your choice of these finishes:

• Polished Brass
• Satin Brass
• Antique Brass
• Satin Nickel
• Antique Nickel
• Antique Copper
• Venetian Bronze

Our YDK71 Solid Brass Door Knocker will  be available on the  www.Your-Door-Knocker.com web site in mid to late August, 2o1o at a special introductory sale price.

Our YDK71 is proudly Made In America

When deciding on hardware for your home, brass is always a good selection. It is available in many finishes, has a long life and is easily maintained.

Before you purchase, you must be prepared for [...]]]> The entrance way hardware on your home may seem like a small detail. In reality it is an important consideration.

When deciding on hardware for your home, brass is always a good selection. It is available in many finishes, has a long life and is easily maintained.

Before you purchase, you must be prepared for some surprises, you see, not all brass is the same.

The first thing to be sure of is that your purchase is in fact brass. Modern methods have become quite proficient in plating brass over less expensive metals such and making it look convincingly like the part is made of solid brass . This is especially hard to detect when purchasing packaged items.

Brass is primarily an alloy of copper and zinc. Not only can the proportions of the copper and the zinc be altered, other ingredients such as tin, nickel and or lead may be added in varying proportions to make the finished product cheaper or better suited for a specific job.

This is one of the reasons that the brass valve for your garden hose may not be the same color or texture as the brass that makes up your door knocker. While both are made of brass, the composition of the brass in each product is different.

In our case at Your-Door-Knocker.com, we do not produce water valves, we produce quality ornamental parts such as door knockers. We require brass that is conducive to molding and will machine and finish well.  Our parts must stand up well in the outdoors , in direct sunlight and be resistant to the weather. In short our brass is more expensive than the brass used for water valves.

We do not need to be chemists to purchase the correct brass. Brass has been around a long time. Industry standards and specifications have been written and proven worthy. These specifications provide the foundries and the manufacturers with a common language which ensures the correct grade material is being purchased.

There are manufacturers that attempt to lessen the manufacturing cost of their products by altering the chemical makeup of their brass. For example, zinc is cheaper than copper so the higher the zinc content, the cheaper the brass will be. Unfortunately, once the zinc content passes the optimum amount the quality of the finished product will suffer.

For a manufacturer of quality products it is simply not worth it to cut a couple cents per pound from the casting brass cost. While a door knocker made of quality material may cost a bit more, the longevity of the item will certainly make it the better value in the long run.