DIY Network

Redwood Garden-Gate: Copper-Patina Panel From "Wood Works" episode WWK-607

	The colorful pattern on the gate's copper panel was created using chemical and heat reactions.
	The controlled chemical-reaction creates a uniquely patterned patina finish.

With the frame for the garden gate built, work can now begin on creating the copper panel and patina finish. The aged and colorful patina look is created using chemical and heat reactions.

Materials used for copper panel and patina finish:

Copper sheet (48-oz. copper; 1/6" thick)
Jig saw
Random-orbit sander
240-grit sandpaper
Blow torch and propane
Cupric nitrate
Ferric chloride
Zinc oxide
Spray degreaser
Sponges and rags
Garden hose and sprayer
Spray bottle and water
Masking tape

Safety equipment:

Charcoal respirator
Protective gloves and apron
Safety goggles

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

Safety Alert: Always wear protective gloves and eye protection when working with toxic or caustic chemicals. Work outdoors or in a well-ventilated area. Dispose of toxic substances responsibly.

Safety Alert: Use extreme caution and follow appropriate safety measures when working with a blow torch or flammable materials.

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	Figure A
	Figure B

Copper Patina

• For the copper panel, you might opt for a thin sheet of copper laminated to a piece of plywood. For our gate, we used a sheet of 48-oz. copper, which is approximately 1/16" thick.

  Important: If you opt for the less expensive copper-laminate and plywood method, make certain to create the patina before laminating as the heat used in the patina process can cause the glue bond to fail.

• Use a jig saw to cut out the panel (figures A and B).

  Safety Alert: The edges of the cut copper may be sharp or jagged. For protection, wear gloves.
  

  	Figure C
  	Figure D

  
  
  

• Use a random-orbit sander and 240-grit sandpaper to sand the copper surface (figure C). This will remove any film, wax or oil, but will also etch the copper surface, giving it a mechanical "tooth" so that the patina will adhere properly.

• To create the colorful patina on the surface, you'll need to use a combination of ferric chloride, zinc chloride and cupric nitrate.

  Safety Alert: When working with these caustic chemicals, always wear a charcoal respirator, goggles, gloves and an apron. Work outdoors for adequate ventilation. Because the chemicals are caustic, avoid skin contact.

• In a cup of hot water, mix 1/4 teaspoon of ferric chloride and stir.

• In another cup of hot water, add 1/4 teaspoon of cupric nitrate (figure D) and zinc chloride.
  

  	Figure E
  	Figure F

  
  
  

• Apply a degreaser to the copper to remove any remaining manufacturing oils.

• Rinse off the surface with water using a garden hose and sprayer (figure E).

• The surface is now prepared for the patina treatment. Use a blow torch to heat the copper to 300 degrees Fahrenheit (figure F). You can test the temperature with water from a spray bottle. It should steam and sizzle on the surface.

  Safety Alert: Because the intense heat will cause the chemicals to fume, it is essential to wear a mask and goggles at all times during this process.
  

  
  
  

• Use sponges, saturated with chemicals, to blot the solution onto the hot surface (figure G).

• Alternate between dabbing on the ferric chloride and cupric nitrate/zinc solution (figure H).

  Figure G

  Figure H

  
  

  
  
  

• Flame the copper with the blow torch (figure I), and you'll see results instantly.

• Spray with water and repeat the process. Continue until you are happy with the results (figure J).

  Figure I

  Figure J

  
  

  
  

In the segment that follows, David Marks applies a wood finish to the frame and installs the copper panel in the garden gate.

RESOURCES :

The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com