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
Wood I purchased for the body frame
● 1½” x 3½” (90mm x 45mm): 10 pieces @ 80″ (2m)
● 1″ (25mm( 1/4 round: 4 @ 80″ (2m) and 4 @ 40″ (1m).
● 11/16″ (18mm) plywood: 1 piece @ 36 1/4″ (906mm) square, and 1 piece @ 34 1/4″ x 79″ (856mm x 1975mm)
Step 2.1. Shaping the frame members
The frame pieces for the telephone box body were made out of 2″ x 4″ (100mm x 50mm) wood.
The actual or true size of the above mentioned wood was really 1½” x 3½” (90mm x 45mm) because it was dressed (smoothed, planed, surfaced).
However, the frame pieces had to be shaped to incorporate a decorative ‘corrugated’ bit. In short, they had to be shaped as shown in the drawings below – the before and after drawings.
Out of 2″ x 4″ (100mm x 50mm) lumber we shaped frame pieces using a circular power saw, an electric hand planer, and sand paper.
First we marked where to cut the grooves on all of the frame pieces.
We marked and grooved 10 pieces of 1½” x 3½” (90mm x 45mm) lumber @ 80″ (2m) long.
The groove cutting measurements:
There were 4 cuts (grooves). They were 1/8″ (3mm) wide and 1/4″ (6mm) deep.
From the edge inwards, the markings were 3/8″ (10mm), 1/8″ (3mm), 3/8″ (10mm), 1/8″ (3mm),3/8″ (10mm), 1/8″ (3mm), 3/8″ (10mm), and 1/8″ (3mm) – with the 1/8″ (3mm) mark being the cut.