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 4.7. The acrylic sheet
For the door and the two windows I used 3/16″ (4.5mm) thick acrylic sheet: 1 @ 21 5/8″ x 60″ (540m x 1500mm) and 2 @ 22″ x 60″ (550mm x 1500mm) respectively.
Note: Acrylic sheeting is widely known as Plexiglass. Plexiglass, however, is the name given to acrylic sheeting manufactured by Atofina. The same acrylic type sheeting is also known by the names Acrylite, Lucite and Perspex. I’ll refer to it simply as acrylic sheet.
I laid each door and window unit face up on a flat work surface.
To each door and window unit I placed an acrylic sheet on top of its fixed grid.
I then placed a second grid on top of that, so each acrylic sheet was sandwiched between two grids.
I turned the units over on a packing piece to keep the weight on the grids.
I drilled through the top grid and the acrylic sheet.
I made the drill size bigger than the screw shank and honed back the point of the cutting edge of the drill to make it easier to drill through the acrylic sheet.
I screwed the grids (through the acrylic sheet) together.
I then added brackets to the sides of the window frames, four each side.
This would make it easy to fix the windows to the telephone box.