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
Chapter 1: The Head
Overview of the head
The head was the most involved (and probably the most exciting) section of the project. It touched on four crafts: woodworking, lightweight concreting, fiberglassing, and painting.
The head was made up of the following (in the order of making):
● The side-frames, out of 2″ (50mm) thick wood.
● The inner support structure.
The inner support structure comprised the cross-section and diagonal-section pieces that were used to support the roof until the different applications (hypertufa, slurry) cured or set.
Most of this was then be removed.
The inner support structure from a looking down point of view was sort of like an eight-spoked asterisk ✳ .
● A layer of hypertufa (lightweight concrete) about 1¾” (45mm) thick.
● A thin skim of slurry (a paste-like mixture of cement and water).
● The side-covers, out of 3/16″ (4mm) plywood.
● A thin cover (roof only) of fiberglass.
The first thing that I did after looking at a trillion photos, was to play around with design on paper.
I eventually came up with my final working drawings. My plans.