THE FORGE
Every project we take on has a story. From unusual challenges to bespoke creations, we love sharing how we turn ideas into high-quality, functional and stylish metalwork. Explore some of our favourite builds and see the craftsmanship in action.
The 20th Century Lantern Rebuild
25/04/26
Project Overview:
A new client approached J.M. Metalcrafts on the 11th of February 2026 with a very unique challenge: his beloved 20th century garden lantern was in need of a full rebuild after having many years putting up with good old British weather. Our challenge was keeping the 20th century looks in a brand new rebuild.
Our first look!
Seeing this, we knew this was going to be a big job. Very exciting!
The Lantern...
After removing the roof, door and old glass panels, we could see this would definitely need rebuilding. This was in no state for a refurbishment.
Paintwork
Refurbishing the roof... the first step taken on the rebuild whilst waiting on materials to be delivered.
Paint Removal
Mostly removed with a wire wheel and polished lighlty with an orbital sander.
Material Shows up
Straight to work on the cage frame. It was coming together piece by piece. Fabrication to the millimetre.
Framework for the door...
Made with solid 8mm square mild steel bar and 16mm by 3mm thick flat bar. Was looking fancy! Hung up for its zinc galvanising paint undercoat.
Zinc Galvanising Undercoat
Here the cage frame, ladder bar and frog collar have been all welded together with TIG & MIG processes. with the undercoat applied. Looking amazing!
Time for a lick of paint!
Our client had supplied us with the original paint used on the old lantern and requested that all parts were to be hand painted with a brush to keep its 20th Century look.
Some more paint...
The colour was brilliant. Such a gorgeous tone of red!
The Door
Before this lick of paint, weldable barrel hinges and a hand-made latch were welded in place on the door frame.
The Finishing Build...
With new glass panels fitted, the door fitted with a seal for the door (for Britain's rainy days) and the roof reattached with the decorative corner pieces, all that was needed was a nice polish up on the glass inside and out ready for delivery and re-fitting
Re-fitted!
What a gorgeous day it was for the re-fitting. It looked stunning up there!!!
Behind the Build: Bespoke Stainless Steel Frame for Custom Cushion
26/09/2025
Project Overview:
Matt Hignett approached J.M. Metalcrafts with a unique challenge: a bespoke, oddly-shaped cushion designed to help wheelchair users improve personal hygiene and comfort, especially while on holiday in Portugal. He wanted a durable, high-quality piece that was both functional and visually impressive.
The Very First Sketch
When cushions get creative, sometimes all you need is a simple frame...
Further into the production there we other parts added in like frame supports and a handle.
The Challenge
The cushion’s unusual shape made measuring and designing the frame tricky, and stainless steel can be tricky to work with. Matt had a very specific vision that needed to be brought to life while staying within his budget.
Our Approach
We chose grade 304 stainless steel (TIG welded) to create a strong, polished framework. The frame was made using:
- Box section for the main structure
- Flat bar for support and fixing points
- Plate for secure attachments
- Tube for a smooth, comfortable handle
Throughout the process, we kept Matt updated with progress and offered expert advice, ensuring every detail met his expectations. Once completed, the frame was painted with a silver zinc galvanizing paint for a strong protective layer and a sleek finish.
Close-Up TIG Welds
Welded to perfection... or until the next coffee break!
You have to love seeing those colours on the welds, it is always satisfying.
Interested in a bespoke metalwork solution? Get in touch today to discuss your project!
The Result
The finished frame perfectly complemented the cushion, creating a sturdy, reliable, and stylish solution that Matt could take to Portugal for holidays and beach outings, making personal care much easier. The project successfully balanced functionality, durability, and budget considerations.
Client Feedback
Matt was thrilled with the final product (read his review). It was a pleasure working with such an enthusiastic, friendly and inspiring client. We’re proud to have been able to bring his idea to life and craft something that is going to improve comfort and independence.