Hi Gordon and all All: Some thoughts on early 20th century cornice problems (endemic in the Northeast and Chicago). Check out:
*Standard Practice in Sheet Metal Work (1929) from SMACNA.org, a manual of original period details (this sheet metal trade org. began with cornices before HVAC)
*GFRC (glass fiber reinforced gypsum) as a substitute/repair material; Towne House Restoration does this work in NYC
*Ditto fiberglass (Architectural Fiberglass Corp. in NYC specializes in this work)
*W.F.Norman in Nevada OK (still offers some galvanized steel cornice parts)
Hope this helps -Gordon
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Gordon Bock
Principal
National Archives Associates
Kensington MD
Original Message:
Sent: 09-22-2016 20:53
From: Michael Malinowski
Subject: ornamental sheet metal
Hi Gordon
We have faced this situation a number of times and have saved the historic fabric by using automotive bondo, along with typical fiberglass mesh and/or light gage sheet metal backing as needed for areas that have 'little to no' metal left. This has been successful even where there was dramatic deterioration. I don't know that this type of work falls into any traditional 'trade' category but many craftspeople are familiar with the use bondo for car body repair; it is readily available.
If complete replacement is needed, there are artisans who can work with metal replicating just about anything - but repair may be easier.
We also just used the 'bondo' approach on a badly damaged 50 year old aluminum facade with success, with a silver spray paint closely matching the visual character of the undamaged aluminum nearby.
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Michael Malinowski AIA
Applied Architecture, Inc.
Sacramento CA