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Lighting fixtures from Yellowstone's Old Faithful Lodge sandblasted & powder coated

2010-03-10T15:48:52Z

New Haven, CT - The restoration of 188 historic gothic-style pendant lighting fixtures from Yellowstone National Park's Old Faithful Lodge is nearing the final stages of completion.

The fixtures are currently in final assembly, where they will be wired, and tested in compliance with UL testing procedures. A total of 1184 panels of medium amber colored, Wissmack-type glass with a dew drop pattern coated in a 3M SCLARL #150 safety film will be installed in fixture's frames. The historic fixtures will then be packaged and crated for the journey back to the lodge for delivery early April.

]]> The restoration of the historic luminaires began in December with the repair of numerous bent spears and twisted frames. Many frames had required re-assembly as older rivets had broken free, compromising the structural integrity of the entire fixture. The top loops were modified from their original design which had accommodated a 1/8" threaded rod, to accommodate a new 1/4" threaded rod that would be better suited for the SVT cord and porcelain socket configuration requested by the park.

Originally, Grand Light was asked to clean the fixtures while preserving the original finish. Our artisans tested 3 cleaning formulas before selecting the best formula for the various metals (Aluminum, Steel, and Galvanized sheet metal) and current condition of the fixture finish, yet even the best outcome was not satisfactory. After testing and inspecting several samples, there was a significant indication of existing fixture finish failure. It was then suggested refinishing the fixtures would be a better solution, thereby insuring decades of continued service to the park.

Once agreed upon to refinish all of the historic luminaries it was determined that a 15% gloss black powder coat finish would be applied. This was the best coating option for the aging galvanized steel frames which had blistered and hardened in a drip formation on several of the fixture frames. The powder coat finish applied 3 to 4 times as thick the paint, thus creating a much smoother finish. In addition, the powder coat is 100% more durable than the paint, will not flake, and will offer 3 times more corrosion protection for these historic fixtures.

The first step in the powder coating process was plastic bead blasting in order to remove all surface contaminants and previous coatings of paint.

Next, the fixtures were sand blasted to achieve a smooth, uniform surface in preparation of powder coating. Once blasted to the bare metal, the fixtures are then submersed in a pre-treated rinse bath removing all particles that have attached to the surface of the fixtures.

After the surface of the fixtures are prepared the 15% gloss black powder coat was then electro-statically applied each individual metal component.

Following the application of the powder coat, the components were sent down the line to the gas fired conventional oven set at 400 degrees Fahrenheit for approximately 15 minutes. When the fixtures exited the oven, the powder began curing on the surface. This process is described as "thermo-set", in which the molecules cross-link, preventing the powder from ever getting soft and flaking from the surface.

Powder coated fixtures await rewiring & reassembly.

Some of the 198 freshly powder-coated components from Type A, C & D fixtures.

Fixtures are undergoing final inspection prior to final assembly.

Exactly 216 socket assemblies were prepared for the restored originals and 28 replications.

For more information about this project including additional photos, please view the project page.

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About Grand Light:

Grand Light, located in New Haven, Conn. since 1929, is an experienced restorer of historic lighting fixtures and a manufacturer of custom lighting fixtures. We have restored, replicated and manufactured custom lighting fixtures at every scale. Past projects include work for clients such as Yale University, Minute Man National Historical Park, the Shubert Theater, the New Haven Museum and the Otesaga Resort Hotel.

Wall mounted lighting fixtures from Yale University's Morse & Stiles Colleges refinished & restored

2010-03-08T21:15:27Z

New Haven, CT - Work continues on the restoration of lighting fixtures from Yale University's Morse & Stiles Colleges.

]]> To date, a number of bronze wall sconces have been retrofitted with energy efficient components and refinished. These fixtures were originally the work of Oliver Andrews, a well known and respected California sculptor, author and educator at UCLA, who was commissioned by architect Eero Saarinen during the building's construction in the early sixties.

The restoration and modification of the existing luminaires consisted of the electrical wiring, custom component fabrication, testing, cleaning, and refinishing of the fixtures.

Grand Light's artisans cleaned and refinished the existing bronze patina of the fixture, as well as the black painted ballast-lamp housings. The fixtures were thoroughly inspected, new ballasts and lamp holders were installed, and the fixtures were rewired and tested in accordance with UL standards.

The image above shows type AD4 both before and after restoration, with ballast & housings.

Before/After Comparison of Type AD4 Fixture

An Illuminated Type AD4 Fixture - Completed Restoration

Those interested in following the progress of this project can visit the project page.

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About Grand Light:

Grand Light has restored, replicated and manufactured custom lighting fixtures at every scale, including various projects at Yale University, the Lincoln Square Theater in Decatur, IL., The Otesaga Resort and Hotel in Cooperstown, NY., The Shubert Theater in New Haven, CT., and other prestigious projects nation wide.

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Fabrication of custom chandeliers for Tower Hill First Presbyterian Church nearing completion

2010-03-03T19:42:23Z

New Haven, CT - The frames of four custom chandeliers being fabricated for the Tower Hill First Presbyterian Church in Red Hill, New Jersey are now complete and will soon be given an antique brass finish.
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Many of the decorative components for the fixtures have been assembled from stock parts, but a few components have been custom-made by hand. The finial in the image above is an example of a hand-made brass component, which was fabricated for the top of each of the four chandeliers.

This image above shows some of the decorative rosettes lining frames of the three large chandeliers.Similar rosettes have been added to the smaller chandelier, which can be seen in the image below.

Shortly after this photo was taken, one of the custom decorative brass finial was attached the top of the chandelier. Additional photos will be posted once the fixtures are completed.

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About Grand Light:

Grand Light has restored, replicated and manufactured custom lighting fixtures at every scale, including various projects at Yale University, Minute Man National Historical Park, the Lincoln Square Theater in Decatur, IL., The Otesaga Resort and Hotel in Cooperstown, NY., The Shubert Theater in New Haven, CT., and other prestigious projects nation wide.

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Yellowstone Insider: "Yellowstone Restoration: A Year-Round Process"

2010-03-03T14:30:01Z

Yellowstone Insider, an independent publication covering happenings in and about Yellowstone National Park, recently highlighted Grand Light's efforts to restore and replicate 188 gothic-style pendant luminaires from Yellowstone's Old Faithful Lodge. The full story can be read by clicking here. For full details about the project including photos of the progress, click here.

Yale Daily News: "Wash, rinse, repeat: Restoring the Morse brass lighting fixtures"

2010-03-03T14:19:51Z

The Yale Daily News recently reported on the restoration of the lighting fixtures of Morse and Ezra Stiles colleges, including 10 massive cast brass sculptures. To read the full story, click here. For further details and photos from this project, click here.

Yale Daily News: "A newer, squarer Morse"

2010-02-18T19:19:20Z

The Yale Daily News recently reported on the ongoing renovations on Yale's Morse College. To read the full story, click here. For details of Grand Light's involvement with the project, click here.

Restoration of lighting fixtures from Bodie Island Lighthouse begins

2010-02-03T19:58:58Z

New Haven, CT - The restoration of ten lighting fixtures from the Bodie Island Lighthouse has begun. Built in 1872 on the isolated Body's Island of North Carolina's Cape Hatteras National Seashore, The Bodie Island Lighthouse is one of the most classic settings of American light stations. The structure has a significant history; having been destroyed and rebuilt twice, once by retreating Confederate troops in 1861 who feared the lighthouse could be used as a Union observation post during the Civil War.

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The current Bodie Island Lighthouse was built in the model of the Cape Lookout Lighthouse, and is currently listed on the National Register of Historic Places. It stands 156 feet tall and is located on the Roanoke Sound side of the first island that is part of the Cape Hatteras National Seashore, and is one of the very few lighthouses that feature an active 1st order Fresnel lens.

The corrosive conditions of the seashore have resulted in extensive deterioration of the structure, including ten historic lighting fixtures of the lighthouse's interior. As a part of a major restoration project intended to restore and preserve the structural integrity of the lighthouse, Grand Light was asked to restore seven fixtures from the interior of the structure as well as three fixtures from the nearby Oil House.

The seven lighting fixtures from the interior of the lighthouse were manufactured by Russell & Stoll and constructed in cast iron with a water tight rating. The fixtures had suffered extensive deterioration of the original finish.

To restore the fixtures, all cast iron components will be sandblasted to remove rust and previous coatings of paint, and to achieve a clean, uniform surface. They will then be primed and given two coats of marine-grade silver paint, with two protective top-coats of incralac clear lacquer to prevent future corrosion. New water-tight gaskets will be fabricated and installed upon reassembly.

The adjacent Oil House featured three porcelain RLM-style pendant lighting fixtures, which were also in dire need of restoration. To restore the fixtures, the metal components are being removed and sandblasted. The porcelain reflectors will be cleaned and touched up as needed. While some components will be replaced, the porcelain sockets will be cleaned and rebuilt.

All lighting fixtures will be rewired with UL listed components and tested in accordance with UL standards.

Grand Light's portion of the restoration work is expected to be completed in approximately one week's time. Once the lighthouse is fully restored by the end of 2010, visitors will be able to view the newly restored lighting fixtures as they climb the spiral staircase for the first time in decades.

Photos and additional updates on the progress of the restoration will be posted as the project continues.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Glass is fabricated & cut to match historic glass from Yellowstone Lighting Fixtures

2010-02-02T14:46:29Z

New Haven, CT - Whether a lighting restoration project involves minor repairs or recreating an entire fixtures that had been lost or destroyed, work on historic glass can often require the use of replacement material.
]]> In the case of the lighting fixtures from Yellowstone's Old Faithful Lodge, very few original panels remained, and even fewer were unbroken. Finding a suitable match for the historic glass wasn't an easy task. After extensive research, four samples of glass determined to be similar to what was originally used in the 1920's were sent to the client for approval. From these samples, it was determined that a medium amber colored, Wissmack type glass with a dew drop pattern would be the most suitable match to replace the many missing or damaged panels from the lodge's lighting fixtures.

It was especially important to find an approximate match due to the historic significance of the Old Faithful Lodge, which is in one of the most heavily traveled and areas of Yellowstone National Park.

Old Faithful Lodge in Yellowstone National Park is located opposite the more famous Old Faithful Inn, facing Old Faithful geyser. The Lodge, built in 1923, was designed by Gilbert Stanley Underwood and constructed in the National Park Service Rustic style. The lighting fixtures being restored were in the recreation hall of the lodge, which is known as "Geyser Hall". The hall is used primarily by the staff of the park for recreation purposes, such as basketball games and other sports.

To protect the glass from shattering in the event they are ever hit by a ball or other item, each panel is being coated in a 3M SCLARL #150 safety film. A total of 1,080 panels are being cut for the smaller fixtures, which include 148 originals (Type A, A1 & C) and 28 replications (Type D). An additional 264 panels are being cut for the 40 larger (Type B) fixtures. The process of preparing the panels is demonstrated below.

The textured glass was initially fabricated as large sheets. These sheets were then carefully measured and cut to precisely fit the frame of the lighting fixtures. Once cut, light pressure was applied to separate the sheets into smaller panels.

To prevent the panels from shattering in the event of an accident, 3M SCLARL #150 safety film was applied to each panel individually by hand, ensuring a perfect application.

Once aligned with the panel, the film was pressed firmly against the glass with a squeegee and soapy water solution, eliminating any air pockets and allowing the film to adhere.

Excess film was then trimmed from the edges of the panel with a utility knife.

Heat was then evenly applied to the surface of the film, causing the film to shrink taut, and removing the excess wrinkles and soapy water solution.

A total of 1,344 glass panels have been fabricated and all structural repairs of the fixtures are now complete. Our next step in the restoration process will include the plastic bead blasting of the fixtures' frames which will remove existing coatings of paint to achieve a smooth, uniform surface in preparation of powder coating. The frames will then be given a 15% gloss black powder coat before being wired with UL recognized components, HI-POT tested and reviewed for approval.

For more information about this project including additional photos, please view the project page.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Fabrication of custom chandeliers for Tower Hill First Presbyterian Church continues

2010-01-30T14:22:39Z

Red Bank, NJ - Steady progress is being made on the fabrication of four hand-crafted custom chandeliers for the Tower Hill First Presbyterian Church in Red Bank, New Jersey. ]]>

Once completed, three of the chandeliers will be 15-light fixtures measuring 30" W x 70" H. The fourth chandelier will be a bit smaller measuring 36" W x 36" H and featuring 10 lights. Each chandelier will be given an antique brass finish.

To view the detailed shop drawings which were provided to us by the client, please click here.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Restoration of Yale Morse & Stiles lighting fixtures begins

2010-01-29T17:38:45Z

New Haven, CT - Grand Light has begun the process of restoring numerous lighting fixtures from Yale University's Morse & Stiles Colleges. The fixtures include commissioned work by Oliver Andrews, a well known and respected California sculptor, author and educator at UCLA. ]]>
Subsequently Grand Light's craftsman sampled additional cleaning processes including multiple hand applications of various 3M Scotch Brite pads. These abrasive steps with an inspection and rinse with a proprietary cleaning blend in between removed the deep stains and the heavy surface corrosion levels by a minimum of 60-80%. These additional steps and redundancy were necessary in minimizing any finish damage while attempting to reach the original finish level. This process is demonstrated below.

The process includes 4 scrub cycles at a minimum; some were repeated after the rinse and inspection of the previous scrub results. The first part of this cycle can be seen in the image above, where a proprietary cleaning blend is being applied to the fixture.

Initially a course 3M Scotch Brite pad is lightly used. In sequential cycles the pad is reduced from course to medium, fine, and then very fine.

Once scrubbed with the proprietary cleaning blend, the fixture is rinsed and then hand-wiped with a cloth to remove any residue.

An air hose and subsequent heat gun is then used to air dry the cleaned portion of the fixture. The cleaned area is then inspected, and the cycle is repeated if necessary.

This process removes as much of the crusted corrosion and dirt buildup as possible with minimal penetration thru the original patina to the cast brass. Once the cleaning cycles are complete, two coats of a protective conservation wax is hand applied.

The application of the protective conservation wax is then buffed.

This cleaning process is repeated on each panel of the fixtures, both on the inside and outside of the fixture.

With this process we are now removing layers of crusted material and therefore periodically filter/recycle the cleaning and rinse water, collect and containerize all cleaning pads, rags, water and sludge for proper disposal.

In addition to the cleaning process, all painted elements including chain, ceiling canopy, fixture loops and lamp cylinders will be refinished.

These fixtures have been reviewed on several occasions by two certified conservators whom are members of AIC and NIC in determining the existing condition, finish and various cleaning, conservation, and restoration processes for these sculptures.

All major fixtures on this project require new energy efficient lamping/ballasting modifications and therefore a significant amount of engineering, custom components/hardware fabrication, mock ups, bead blasting, painting wiring, and testing are conducted simultaneously to the finish conservation efforts.

Those interested in following the progress of this project can visit Grand Light's website at http://www.lightrestoration.com.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Custom chandeliers to be fabricated for Tower Hill First Presbyterian Church

2010-01-14T15:44:28Z

Red Bank, NJ - Grand Light has begun work on four hand-crafted custom chandeliers for the Tower Hill First Presbyterian Church in Red Bank, NJ, each of which will be constructed from drawings provided by the client. ]]> Three of the chandeliers will be 15-light fixtures measuring 30" W x 70" H. The fourth chandelier will be a bit smaller measuring 36" W x 36" H and featuring 10 lights. Each chandelier will be given an antique brass finish.

Pictured above and below are the drawings which were provided to Grand Light by a representative from the church. The chandeliers will be constructed with a combination of stock parts and custom components, and then wired in accordance with UL standards and hipot tested.

Photos of the fixtures will be posted as progress continues.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Progress continues on restoration of historic lighting fixtures from Yellowstone's Old Faithful Lodge

2010-01-12T14:45:01Z

Yellowstone National Park, WY - Steady progress is being made on the historic lighting fixtures from the recreation hall of the Old Faithful Lodge in Yellowstone National Park. ]]> To date, all structural repairs and replications have been completed. The once twisted and bent spears at the top and bottom of the fixture have been straightened back to their original shape. Frames that were bent have been straightened, and missing rivets have been replicated and attached to the fixtures.

Many fixtures were missing tabs meant to hold the glass panels. Prior to being removed from the lodge, some panels had been siliconed to the frame as a temporary solution for the missing tabs. All glue has now been removed and new tabs have been fabricated and soldered to the fixture.

With the structural integrity of the fixtures now restored, Grand Light will soon plastic bead blast all surfaces to remove the previous coating and then sandblast them to achieve a smooth uniform surface. The frames will then be cleaned and powder coated in a gloss black, pending the final approval of samples that were sent back to the park.

In the meantime, glass panels have begun to be cut from larger sheets. We are using a medium amber color Wissmach Cathedral Glass with a dew drop pattern for the fixtures. Through extensive research, it was determined that this this type of glass would be the closest possible match available to the original panels of the fixtures; most of which had been replaced with plastic during previous repairs.

Once the glass is cut, each piece will be coated in 3M SCLARL #150 safety film for textured glass. This will prevent the glass from shattering in the event it is ever hit.

For more information about this project, please read the project page.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Yellowstone Old Faithful Lodge historic fixture restoration begins

2009-12-19T17:06:48Z

Yellowstone National Park, WY - The restoration of 188 historic lighting fixtures from the Old Faithful Lodge at Yellowstone National Park has begun. The fixtures will undergo a series of different processes before they're released back into the lodge to ensure they are free of defect, durable, and will continue to service the lodge for the next 100 years.]]>

Once the fixtures were taken apart, each frame was individually inspected for structural damage and defect. All frames that are missing rivots, have bent components, or that are missing components such as tabs to hold glass, will be repaired or will have components replicated. Most structural issues appear to be on the top and the bottom spear portions of the fixtures, where there are twisted and bent, and require straightening. Some of the fixtures frames are bent and have missing rivots which hold the fixtures together, all of which will be straightened and replaced.

Pictured on the left is a typical fixture needed structural repair. They have the bent upper and lower spears as well as twisted frames. One the right is the same frame as it undergoes the structural repair process of this project.

Lantern from Philadelphia Shrine restored and replicated

2009-11-16T16:23:51Z

PHILADELPHIA, PA - The replication and restoration of a large outdoor lantern from the Shrine of the Miraculous Medal has been completed. ]]>

The original fixture, seen on the right in the photo above, was located near the front entrance of the Shrine of the Miraculous Medal. To restore the fixture, the frame of the lantern was removed from the pole, and all individual components were disassembled so that they could be individually inspected for damage and repaired as needed. Once disassembled, the frame, pole, and individual components of the fixture were glass-bead blasted to smooth the surface profile and to remove all undesirable residual contaminants; preparing the surfaces for the powdercoat.

Numerous holes that were drilled to hold plastic panels during a previous repair were filled in, and copper tabs were soldered to the lantern's frame for the purpose of holding new glass panels.

Each component was then individually replicated and reassembled to form an identical match of the original. As a final step, the original and the replication were given a matte-black textured finish and then wired in accordance with UL standards. Both the original and the replication can be seen in the image below.

Above is a close-up view of the base of the fixtures, which will mount to a stone column. The full fixtures can be seen below, crated for shipment back to Pennsylvania.

To see how the fixture looked prior to restoration, click here. For more information about this project, please read the project page.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.

Grand Light travels to Yellowstone National Park to remove lighting fixtures for restoration & replication

2009-11-10T21:51:04Z

Yellowstone National Park, WY - Grand Light recently dispatched a two-man team to the historic Old Faithful Lodge to remove and transport 188 lighting fixtures from Geyser Hall for restoration and replication. ]]> Old Faithful Lodge in Yellowstone National Park is located opposite the more famous Old Faithful Inn, facing Old Faithful geyser. The Lodge is constructed in the National Park Service Rustic style, and includes dining spaces and a recreation hall, known as Geyser Hall. The roof structure of Geyser Hall is reminiscent of Gothic wood construction, with a height of 73 feet to the ridge. The Lodge was designed by Gilbert Stanley Underwood and was built in 1923 with additions in 1927. The Lodge is included in the Old Faithful Historic District.

The current Old Faithful Lodge is a result of numerous changes dating back to the early days of tent camps. These camps were erected throughout the park and offered shelter before hotels and lodges were built. By the 1920's, auto traffic into the park was increasing dramatically and it was determined that the tent camp at the site should be replaced with a permanent lodge.

Following a site visit earlier in the year, Grand Light was selected to restore and replicate the lighting fixtures from the historic Geyser Hall. Rather than risk loss or damage in transit via a common carrier, Grand Light dispatched a team to Geyser Hall and carefully packed and transported the historic fixtures 2,400 miles back to Connecticut. These fixtures include 148 historic gothic-style pendant luminaires, of which 28 will be replicated, as well as 40 larger historic luminaires of the same style.

Grand Light will clean all luminaire components, inspect and repair all mechanical defects, replace all existing electrical components with UL listed products, rewire and hipot-test the fixtures. To restore the historical integrity of the luminaires, previously installed plastic panels will be replaced with historically accurate medium-amber glass, and all undamaged original glass panels will be cleaned and re-used.

"Old Faithful", which could be seen nearby as Grand Light's team removed the lighting fixtures from the Lodge.

A view of Geyser Hall in the Old Faithful Lodge with all of the historic lighting fixtures removed and packed for transit back to Connecticut, where they will be restored, rewired, and replicated.

For more information about this project, please read the project page.

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About Grand Light:

Located at 580 Grand Avenue, New Haven, Conn., Grand Light has been serving the interior and exterior lighting needs of homeowners and professionals since 1929.