Welcome to Wil-Clair.com! - sheet metal fabrication, sheet metal work, sheet metal architecture

How We Do It

Case Study 1 - Local Cereal Manufacturer - Industrial

Case Study 2 - Bartle Hall - Architectural

Case Study 3 - Tabernacle at Queen of the Holy Rosary

Case study 4 - Local Coffee Plant - Industrial

Case study 5 - St. Patrick’s Church - Artistic

Case Study 6 - Board of Public Utilities - Industrial

Case Study 7 - Farm Entrance - Artistic

Showcase Article
Ingram's Magazine and SMACNA Feature CEO John Svetlecic in an article that focuses on Industrial Sheet Metal Applications.
Click here to download the full article

Case Study #1 - Back to Top

Local Cereal Manufacturer - Industrial

Problem:

Unclean air penetration: FDA requires air to be filtered and ran through duct, which is 100% food grade compliable, while blowing on food during manufacturing process.

Wil-Clair’s Solution:

	Filter the air using HEPA filters.
	Pass the air through stainless steel duct using heliarc welding process, to 100 grit on the inside.
	All joint connections are slip joints going away from air flow and sealed with food-grade silicone.

Case Study #2 - Back to Top

Bartle Hall - Architectural

Problem:

	Original drawings called for anodizing materials. However, no dip tank was large enough to accept the structure in one piece as originally constructed.
	How to run electricity to the signs for lighting purposes without exposing wire sources
	Expansion/contraction of aluminum lighting holders at 360 foot length

Wil-Clair’s Solution:

	Wil-Clair researched a way to give the impression of anodizing the material. Anodizing is a procedure where the aluminum material is dipped, causing the surface to become hardened, scratch resistant, and resists ultraviolet light fading. The alternative was to powder coat the mammoth structure. Powder coating gives the same results for UV protection and scratch resistance. Powderized paint is sprayed and processed through an electrical charge which melts the paint to create a uniform paint seal.
	Wil-Clair suggested and fabricated holes within the signage fabrication itself. These holes allowed for feeding the wires through the rectangular tubing. The wires needed a special coating to resist the heat penetration during the powder coating. This would work for the temporary wire run setup. The permanent wires were fed through, utilizing the temporary wires as the pull-wire feed. This was a critical step to facilitating the electricity to the signage without exposing the wiring for cosmetic purposes.
	To accommodate Kansas City’s various temperature extremes, there needed to be some sort of “give and take” within the aluminum so as to not disturb the lighting of the signage throughout the seasons. Noting the temperature effects on the various metals used:
	Aluminum will move ¼” per every 50 feet when temperature fluctuates from 0-100 degrees. Steel however, moves on 1/16”, hence 1/3 of what aluminum will do.
	The lighting encasements are made from steel, whereas the signage is out of aluminum. Wil-Clair created slip joints within every 10 feet so the whole structure itself will move with the temperature fluctuation. This way the lighting will remain properly placed on the signage, eliminating the risk of the lighting in the aluminum to stress and fall through. A machine joint was used so none of the lighting would seep through the cracks and consequently hinder the cosmetic effects of the signage lighting.

Feel free to view the signage along the 13th and Broadway underpass located in Downtown Kansas City.

Case Study #3 - Back to Top

Tabernacle at Queen of the Holy Rosary

Bronze Tabernacle Front Display
April, 2004

	Wil-Clair consulted with the architects during the design stages of the project. The team was envisioning a wheat display, focusing on texture and color, but not sure as to what steps to take to achieve. Hence, they knew what they wanted but didn’t know how to make it happen.
	Wil-Clair researched various possibilities. Initially, WC outsourced metal balls for grapes. Upon further investigation, actual grape and leaf clusters were located. Concerned that the color wasn’t ideal, WC took the templates to a bronzing shop for color embellishment and texture dimension. With architect approval on color, the next step was to create the wheat.
	Wil-Clair utilized 3/32” bronze welding rod for the wheat stems and feather tops (head, seeds and beard) and 1/8” bronze welding rod for the arc and curve pieces that run throughout the display.
	With all the pieces for the display gathered, the architect and Wil-Clair pieced together the puzzle for the final look. The two tablets each hold 75 pieces that are glued on by using a clear epoxy.
	In order to give the tablets a finished, realistic appearance, Wil-Clair utilized its CADD system to design and construct and enhance the sunrays. Hidden fasteners are used around the perimeter of the glass to suspend and protect the sculpture.

Feel free to visit this metal masterpiece at:

(913) 432-4616
7023 W 71ST STREET
OVERLAND PARK, KS 66204

Case Study #4 - Back to Top

Local Coffee Plant

Problem:

	must abide by FDA standards
	need to keep food particles (coffee grounds) from accumulating in crevices and cracks within tanks and hoppers
	microorganisms of food accumulate and have potential to contaminate food, possibly causing illness to the consumer
	as coffee grounds are dumped from hopper to holding tanks, dust clouds are released into space, causing workers to need Upper Respiratory masks
	material needs to be at 120 grit grade cleaning

Wil-Clair’s Solution:

	design and fabricate a stainless steel tank where bottom encompasses a slidegate flange to ensure a proper sealing mechanism
	construct a flexible outlet that will be spring-loaded utilizing UHMW plastic. This will attach to the hopper below providing a 99% proof sealant, therefore eliminating the dust particles escaping into the air and any loss of spilled product.
	use the cold fusion heliarc process which will be more cost effiecient for coffee company, and will be compatible to 140 grit grade cleaning specifications
	Cold fusion ensures no cracks or crevices within the welds and metal object This is important in food production so that no micro-particles of food get trapped, and over time begin to contaminate the food production process as it passes through
	construct prototype for approval for coffee manufacturer’s Review Panel
	upon prototype approval, construct multiple replicas for project completion

Modifications:

For prototype purposes, the sight glass reinforcements were tack welded. Upon continuous full welding, consider warping occurred across the glass. FDA requirements are for continuous weld, via food contamination regulations.

The warping predicament was corrected by utilizing a cross roll and stress release technique which brought the reinforcements back to a flat surface.

	Surpass standard 120 grit grade cleaning for 3 reasons:
	Exceed FDA requirements
	cold fusion heliarc brings the product to 140 grit grade
	process is far more cost effective for the client
	Typical process to reach 120 grit is weld and grind which averages 20 minutes per foot
	Cold fusion averages 11 minutes per foot

Wil-Clair’s resources in action to create the product:

	High end Miller Heliarc welding machines
	230+ years of combined journeymen experience and insight
	Head Project Journeyman: Terry Roberts
	Cold fusion ensures no cracks or crevices within the welds and metal object. This is important in food production so that no micro-particles of food get trapped, and over time begin to contaminate the food production process as it passes through
	construct prototype for approval for coffee manufacturer’s Review Panel
	upon prototype approval, construct multiple replicas for project completion

Head Project Journeyman: Terry Roberts
•	27 years in sheet metal industry
•	Longview Welding Inspectors Certification - all phases (Stainless, Carbon, Aluminum, Galvanized, Horizontal, Vertical, Overhead Arc)
•	4 year Apprentice to Journeyman Training Program-Course of Instruction and Performance Application
•	Experience in ductwork, architectural, industrial, and kitchen disciplines of sheet metal trade

*By request of the local coffee manufacturer, the name of the company is not disclosed in this document.

Case Study #5 - Back to Top

St. Patrick’s Church

Problem:

Wanted to bring an aura of Ireland to the forefront in the new worship space.

Wil-Clair’s Solution:

Wil-Clair was able to provide assistance and accommodate their classifications with the following accessories:

Cross Holding Pedestal

This was architecturally designed to be a nine piece aluminum structure that would utilize the surrounding wood as the support structure. With careful thought and review, Wil-Clair envisioned a way to fabricate the aluminum sections as a one piece circular cut-out. This replaced the nine individual pieces and in itself become the structure for the wood. The texture and design theme of the metal cut-out identically matches the valticino configurations in the following pictures.

Cross Pedestal Enclosure

Problem:
	On occasion cross kept falling out of pedestal
	Initial mechanism (ball bearing and lock device) was somewhat cumbersome getting individuals to push the cross back through to the locked, stationary position

Solution:
	Fabricate a hinged front panel to be polished on both sides – so when door is open it displays the same artwork and texture as that on the outer panel
	Install a spring loaded locking device to the door and the casing, so if the cross should slip forward out of the ball bearing mechanism, it will be stopped by the locked panel
	Align the top rim of the panel with rubber cushion to alleviate any scratches or dings to the cross piece

Bell Tower

This structure was created with the assistance of the CADD Cutting System. Its purpose is to resemble the architecture of old church huts in Ireland during the 11th and 12th centuries. The internal make-up of the piece is such that it holds 80 pound drivers and speakers. None of this can be detected from the exterior. A “hidden door” was installed in the back to allow for easy access to the electronic equipment.

Valticino

This was originally configured to be constructed in 12 individual sections. After studying a three-dimensional paper model, Wil-Clair envisioned many methods to reduce the number of pieces to six and provided the structure with the illusion of hanging in air. All-thread rods were inserted within the metal tubing to act as the support mechanism. From there, shape cuts were inscripted to create notches and slots for an eyelet fastening connection between the 6 pieces. These eyelets were constructed to “slip-fit” into one another’s common tube connection and hide any external fastening devices. This provides the valticino with a magnificent “one-piece” illusion. The wood framing is merely a cosmetic touch to help accent the crucifix design and texture, of which was developed solely through Wil-Clair’s CADD Cutting System. Due to the internal suspension within the 6 pieces, the “floating in air” illusion was much more feasible to implement as a result of the design change.

Tabernacle Light

Problem:
	Candle has a burn time of 30 days
	Changing the candle needs to be easily accessed
	Mechanism hangs from the ceiling on a cable and is placed 3 feet away from the wall

Solution:
	Acquire and install an industrial strength spring loaded drop light reel in the ceiling
	Fabricate and attach a hook device on the bottom of the light fixture, making sure it blends well in the fixture’s artwork.
	Acquire a 2 foot pole with a hook device on the end
	Use 16 gauge cord within the reel and install a cone that will work with the spring tension to stop the cable when releasing and retracting at the exact lengths so light will return to identical location each time

Celtic Cross

Created out of 5052 aluminum, this is a truly unique structure. Since this piece would need to withstand outside weather conditions, the 3 dimensional template detailed holes within the design to accept extreme wind forces. Unflat expanded metal was used as the imbedded dye tool in conjunction with our digital hydraulic press roll to create the aluminum indentations. The ¼” aluminum was rolled under extreme pressure to get the indentation, but then was re-rolled in the opposite direction to flatten and achieve the desired texture. The structure is anchored in the corners with hidden fasteners within the base to allow for ample fluctuation to keep the studs level. A hidden door is in the back to provide easy access to the support studs. This cross can withstand a wind force up to 225mph. The cross cut-out molds that expose the inside of the metal configuration, were custom designed. The tooling dye, a stencil for metal shapes, was destroyed along with the cut-outs to guarantee its authenticity as a truly unique masterpiece.

Feel free to view these sculptures in person. St. Patrick Church is located off of I-29 and the Davidson Road exit.

St. Patrick Church
1357 NE 42nd Terrace
Kansas City MO 64116
816-453-5510

Case Study #6 - Back to Top

Board of Public Utilities - Industrial

Problem:

	Customer needs junction closures for multiple outdoor conveyors that intersected the buildings.
	Drag belt conveyors had covers over the top for dust control that are not connected to transfer building, causing dust leakage as coal is being conveyed.
	This particular conveyor entered at a declining angle just under the roof line.

Wil-Clair’s Solution:

	Design sheet metal closures from the drag conveyor covers to sheet metal building sides.
	The closure had to be weather resistant, both in function and material.
	This was done to 10 different buildings in various locations. Employees witnessed dramatic results in dust containment.

Case Study #7 - Back to Top

Problem:

	How to create realistic metal Texas Longhorn Cows
	Client utilized artist from Hallmark Cards to create design/sketch work
	Cows require more than just cutout of perimeter; need definition and texture to appear realistic
	Metal needs to turn to brown for cow color
	Dimensions of each cow: 6' x 12', bull: 7' x 12'
	Mounting to structure so observer perceives realistic cows from 30 feet away (approximate measurement from farm to roadway)
	Wants cows to serve as unique entry to identify farm and house
	Bull is to be mounted to a movable hinged gate

Wil-Clair Solution :

Phase 1:

	Draw up perspective of the artist's creation on paper
	Manufacture a test run out of 22 gauge metal and paint in Rustoleum red
	Measure 30 feet and study long distance effect to naked eye

Phase 2:

	change cutout areas within each cow making each slightly smaller-prior model gave too much definition to face and legs
	repeat whole process as listed above (light gauge, red paint, measure distance)
	utilize CADD TO PLASMA CUTTING SYSTEM to decrease only cutout space by 20%
	call in client for approval of size

Phase 3:

change ¼" to 3/8" plate; angle definition better at this thickness

begin 5 day process to achieve desired coloring:

day 1 - apply sulfuric acid to carbon steel
day 2 - wash off acid
day 3,4,5 - wet it for 3 days to expedite rusting process

call in client for approval of color

Phase 4:

	manufacture final cows (6) and bull
	Art sketches and final cut outs are identical through CADD to Cutting System utilizing Inventor 2000
	1'=1" scale breakdown of paper art to INVENTOR 2000 dimensions
	bull to measure 1' above height of cows

Modifications:

	bull will need to attach to tubular gate
	embedded piece of steel attached to concrete base to simulate grass, hills, and terrain out of steel which was connected to embedded concrete steel on one side and cow hooves on the other - this was done to provide added strength to more delicate areas of cows and fencing so in lieu of being hit, no damage would occur
Feel free to visit this metal masterpiece in Smithville, MO - Take 169 N to Smithville. Turn onto East 92 Hwy. Turn South on Mt. Olive. Go 1.6 miles and display is on the left side of the road.