Table of Contents
- 2The size of the thing
- 3About the measurements used
- 4A visual index
- 5Overview of the head
- 6Step 1.1. The head side-frames.
- 7Step 1.2. The head inner support structure.
- 8Step 1.3. The form (mold) for the hypertufa.
- 9Step 1.4. Hypertufa
- 10Placing the hypertufa
- 11Hypertufa - The curing process
- 12Step 1.5. Slurry
- 13Off with the formwork
- 14Step 1.6. The head side-covers and the crown
- 15The crown
- 16Fixing the trim to the side-covers
- 17Step 1.7. Fiberglass
- 18Step 1.8. Paint - undercoating the head
- 19Overview of the body frame
- 20Step 2.1. Shaping the frame members
- 21Step 2.2. Cutting the frame members to length
- 22Step 2.3. Making the wall frames
- 23Step 2.4. The body frame
- 24Step 2.5. The shackles
- 25Overview of the Neck
- 26Step 3.1. The neck - making the box unit
- 27Step 3.2. The aluminum angle for the sign
- 28Step 3.3. Internal perimeter pieces
- 29Step 3.4. Fitting the neck
- 30Step 3.5. The telephone sign
- 31Step 4.1. The trim around the door and window openings
- 32Door and window overview and plan
- 33Step 4.2. Wood for the door and windows
- 34Step 4.3. Joining the stiles and rails
- 35Step 4.4. Notching the muntin bars
- 36Step 4.5. Fixing the muntin bars
- 37Step 4.6. Painting the door and windows
- 38Step 4.7. The acrylic sheet
- 39Step 5.1. Making the base
- 40Step 5.2. Some painting
- 41Step 6.1. Putting it all together
- 42Some strengthening and the door closer
- 43The desired effect
- 44Step 7.1. The rose and ceiling
- 45Making the rose pattern
- 46Marking, drilling, and cutting the rose
- 47Tapering the rose
- 48Painting and fitting the ceiling and rose
- 49The light goes on
- 50The plans
Step 1.4. Hypertufa
Hypertufa (in a sense) is a lightweight concrete.
Some expert advice: The success of hypertufa depends on the consistency of the mix and the amount of attention paid to the curing process.
Okay! Having read stories about other people’s less than perfect hypertufa attempts resulting in cracked and crumbling end results, I decided to take the above advice very seriously.
My hypertufa mix
● 3 buckets of peat moss
● 2 buckets of perlite
● 2 buckets of cement
● 2 plus buckets of water (more or less)
The peat moss and the perlite was bought from a garden center and the cement from a building supply store.
Some safety stuff: Breathing in any of the above ingredients (except the water) is not good for your health. Wear a mask, goggles, gloves, and appropriate clothing. The ingredients are very light and any wind or mixing disturbance will cause the dust particles to float through the air.
The above dry ingredients were poured (carefully) into a wheelbarrow and mixed together with a spade.
Then the water was poured in slowly – about 1/2 of a bucket at a time – and the mixing continued.
It was mixed with the spade from underneath and folded over. Mixing and adding water continued until the mix was a uniform consistency: wet enough without puddling and able to be spread without crumbling.
Tip: A smaller spade or shovel is easier to work with than a bigger one.