Our front fence is coming along, we bought roughly 55 feet of used iron fence a few months ago with a plan to modify it to use it in our front yard. The fence was too tall (near five feet, was a pool fence). Encroachment limit is 36 inches (thanks GG!), otherwise front is 42 inches.
We had to break the welds that secured the bottom rail to the pickets (it was flush with the bottom). It was a real PITA, ended up using an air chisel, brute force and ignorance... the rails got pretty beat up and bent a little in the process. Once removed they needed to be cleaned up to make sure the pickets fit back trough them. The wife was going to do all this part but she was not comfortable with the air and power tools, but it was good for her to see it is not all that easy....
Then I needed to insert the pickets through the rail, I want the pickets to extend past the rail at the bottom for looks and for possible city forced modification. Each section is now 41 inches tall and the pickets extend 5 inches past the rail. I like the look but if the city comes along and makes us drop the fence to 36 inches we can, I will just cut the extend pickets flush with the bottom rail and drop the sections down (41 becomes 36)....
The fence is hot galvanized. I do not have the "required" respirator so I used a box fan (blowing away from the work area) as a poorman's welding vent hood (preventing welding fume fever), welded on breezy days as well, also applied some previously learned welding breathing techniques... I made a jig out of a 2X4 and also used a woodworking bar clamp to align the rail and straighten them out as I went along. FCAW with a 140 amp Lincoln (see they do work!).. Not the prettiest welds but they are at the bottom of the fence.... and FCAW on galvanized, if there is slag you drag...
The five inches of pickets through the bottom rail was decided because that was the distance between the blade and side of my trusty Hilti circular saw, and it looked good.... I welded along one side, used the flat unwelded side of the bottom rail as a guide and to cut all the pickets to the same length.... then welded that side. Went through two blades and started on a third, this blade was pretty much done....
Paint won't stick directly to galvanized, I powerwashed each section to blow any loose/flaking paint/powder coat off, wire wheeled the heavily oxidized areas and any other loose stuff. Treated them with vinegar to neutralize the remaining oxidized zinc and then applied a primer intended for galvanized on any bare spots (shown section is upside down).
I was originally going to do make the section 36 inches but we did not like the look. I made a couple of test pieces from small sections first.
What we started with....
Painting the sections now (well not today in the rain), hopefully installing in the next couple of weeks.
edit...
PSA/pro tip....having the spouse involved in the hard work is a good reality check and reduces the "why isn't is done yet".... I highly recommend this.