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 1.6. continued
Fixing the trim to the side-covers
The side-covers were placed on a Any broad, thin surface. of soft A piece of sawn, or dressed lumber of greater width than thickness. Usually 19mm (3/4") to 38mm (1 1/2") thick and 75mm (3") or more wide..
The The finish materials in a building, such as narrow boards applied around openings (window trim, door trim) and vertical corner battens. pieces were fixed to the side-covers with glue and small nails.
The nails went right through the A piece of wood made of three or more layers of wood veneer laminated together with glue. and into the soft board.
When all the trim pieces were glued and nailed, the side-covers were lifted off the soft board, turned over, and the protruding A short nail with a large flat head used for securing roofing felt, plasterboard, sheet metal to wood etc. points were bent back against the back of the side-covers.
At that stage both the side-covers and the topmost trim were left slightly over length.
The side-covers were then held in place against the head, marked for length, and cut with a miter saw.
The side-covers were ready to be fixed to the head.
Plenty of glue was applied to the sides of the head as shown in the photo.
I used both glue and nails to secure the side-covers to the head.
I was very careful the glue did not ooze through any of the crown impressions and fill them up –
that would be sort of defeating the purpose.
Next on the agenda?
A dabble into fiberglassing.