Scrap is the last word Brian Mello thinks when he sees a pile of old rusted horseshoes. For the past year, Mello, a Rochester resident, has been creating something new and useful out of those old shoes, using the tools of his trade.

A sheet metal worker for 20 years, Mello began creating designs out of horseshoes after spending time at Reunion Farms, a horse farm owned by his fiancée’s family.

“I start with a rusty shoe. Most of these come out bent from the ferrier. The nails are still in them,” said Mello.

Over the past year, Mello has created coat racks, heart-shaped picture frames (for his customers’ favorite horses, of course), lawn ornaments, and even a table.

To get a shoe up to par, Mello reshapes them, sandblasts them, and runs them over a wire wheel. Depending on the design, Mello cuts each piece individually and welds them together.

“It’s a real dirty process,” he said.

Customers, often horse riders who frequent Reunion Farms, request most of the items Mello has crafted.

“I would rather make something personal for somebody than just try to mass produce and make money,” he said. “I’ll make anything that any body wants.”

Each design fits his customer’s specifications. Mello leaves some designs with the look of brushed metal, sealed with a clear seal while others are coated in bright enamel paint.

“Some people like the vintage look. Some people want brand new,” he said.

Mello said his horseshoe designs are just an extension of his day job. “It’s all custom fabrication. This is easy,” he said.

To contact Brian Mello, call 508-801-3783 or email mxrider797@aol.com.