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 Timber, lumber. The hard fibrous lignified substance under the bark of trees.
● 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 How much the teeth are angled out on a circular saw blade..
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 A mixture of sand, gravel, water and cement which hardens to a stone like condition when dry.) about 1¾” (45mm) thick.
● A thin skim of slurry (a paste-like mixture of A powdery type substance made from a mixture of earths materials such as limestone and shale, which is sintered (cause to become solid mass by heating without melting), ground, and mixed with small amounts of calcium sulphate and calcium carbonate. Cement is activated by water and when mixed with gravel and sand, forms concrete. and water).
● The side-covers, out of 3/16″ (4mm) A piece of wood made of three or more layers of wood veneer laminated together with glue..
● 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.