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 2.4. continued
Quarter-round: I cut four pieces of 1″ (25mm) quarter-round wood to the length of 77¼ (1930mm). The length was from the floor to the underside of the top horizontal decorative trim.
I then fixed 1 piece to each corner with glue and nails.
Step 2.5. The shackles
The top shackles comprised of small square pieces of thin plywood, round button pieces (also plywood), and small blocks of wood sanded to a quarter round shape
I cut four 1¼” x 1¼” (30mm x 30mm) pieces of wood into 2″ (50mm) long blocks.
I glued them to the frames above the 1/4 round and held them in place with tape until the glue dried.
Once the glue had dried, I sanded the corner blocks as necessary with an electric rotary sander to make them quarter-round in shape and finishing flush at the sides to the trim (corrugated bits).
I cut the square pieces for the top corner shackles out of plywood. 8 @ approximately 1¾ x 1¾ (45mm x 45mm).
I cut 8 circles (buttons) out of the plywood 1¼” diameter.
I glued the squares and circles in place and fastened with a small nail through the center of each button.