Kearney ParkFountain
2002–2003

Cast Iron and Zinc Fountain

Dedicated May 30, 1901

This fountain, a gift of the great local benefactor Mr. Charles Hackley to the people of Muskegon and dedicated to Phil Kearney, is made of cast iron and zinc. In time, as often happens to historic fountains, the pool was filled with soil to make a planter. The cast zinc figure at the top was removed and placed in a different fountain that also became a planter.

This project involved the complete disassembly of the iron fountain, the casting of new goat heads that spew water from the upper bowl, the return and restoration of the original zinc figure, Epoxy priming of all iron and coating with silicone alkyd black paint, provision of all stainless steel fasteners, and the forming of a new concrete pool within the cast iron exterior pool liner as originally designed.

Illustrations of the Restoration Process
(click on image to enlarge)

The upper bowl and pedestal after excavation and soil removal.		Excavation of all parts of the iron fountain from the soil.		The underside of the upper iron bowl after corrosion removal by blasting with fiinely powdered glass—a method that does not wear the sharp edges of fine detail as seen in this casting.
A new casting in iron for the missing part of this base. The part is fit and ready to attach by welding. Welding cast iron is tricky because local expansion of the metal from heat can cause the metal to crack.		New goat heads were cast in bronze from these wax patterns made from the one original zinc goat head that was in good condition. The original heads slush cast from soft zinc were subject to repeated vandalism, especially the breaking off of the ears.		Patination of the cast iron goat heads..
Complete disassembly of the iron fountain into all its cast parts for thorough cleaning away of corrosion and complete coating with an epoxy primer to prevent future corrosion.		For optimum prevention of corrosion, each piece receives a coating of an industrial 2-part epoxy (the gray coating seen above). All the parts then receive additional coatings, usually a silicone alkyd that can be easily touched-up or an acrylic aliphatic urethane for the toughest of finishes. The complete coating of each individual piece prevents the corrosion at hidden joining surfaces. In addition, all new fasteners are stainless steel.		The trial reassembly of the cast iron pool sides. Often, original holes must be re-tapped and sometimes modifications must be made for new stainless steel fasteners.
The topmost figure on the fountain is made of cast zinc and was cracked in many locations. Also, originally soldered joints were broken. Here, metals conservator Thomas Podnar is soldering cracks in the zinc, a process that requires considerable skill.		Parts of the zinc figure’s staff had to be fabricated as well as a copper ribbon. These were fashioned to match what appeared in dealer catalog illustrations of this figure.		The base of the original zinc figure was so deteriorated that it could not stand. This lower portion is not visible as it is obscured from view by the walls of the upper bowl. To enable the figure to stand, a new, inner base was fabricated by cutting and soldering plate zinc and attached to the figure by soldering.
A boroscope was needed to assist in working a new water supply line through the body of the zinc figure.		The boroscope enabled the conservator to observe areas where the water supply line was catching on metal inside the figure.		The repaired zinc figure after blast cleaning with finely powdered glass and coating with Tnemec two-part industrial epoxy.
Reconstruction of the iron fountain and concrete pool. The inside surfaces of the iron sides of the fountain were filled with a layer of Colbond’s Enkadrain (www.geosynthetics.colbond.com) to create an air-space and for drainage before dry packing the concrete against it.		Installation of the upper cast iron bowl.		Attachment of the bronze goat heads to the upper cast iron bowl.
One of the cast bronze goat heads.		The fountain assembled but before the installation of the upper zinc figure.		The finished iron fountain