April 24, 2013
The first concrete chair, curing away.

The first concrete chair, curing away.

April 18, 2013
It’s free!  After a lot of prying and forcing, I finally got the blank free of the original mold.

It’s free!  After a lot of prying and forcing, I finally got the blank free of the original mold.

April 17, 2013
You can see the layers.  From left to right: Rubber, caulking, fibreglass, and closed cell foam.

You can see the layers.  From left to right: Rubber, caulking, fibreglass, and closed cell foam.

April 16, 2013
I filled the gap with the rubber that’s to become the blank.  The rubber I used is what is typically used in waterproofing parkades, so it’s very strong.  I added some closed cell backer rod to add some volume and prevent the rubber from sagging too much.

I filled the gap with the rubber that’s to become the blank.  The rubber I used is what is typically used in waterproofing parkades, so it’s very strong.  I added some closed cell backer rod to add some volume and prevent the rubber from sagging too much.

April 15, 2013
Foam was added around the edge of the fibreglass, creating a cavity for the blank.  The foam was some left over packing foam from some new doors we had installed.  There was no way I was going to let them throw it out!

Foam was added around the edge of the fibreglass, creating a cavity for the blank.  The foam was some left over packing foam from some new doors we had installed.  There was no way I was going to let them throw it out!

April 8, 2013
Like a newborn baby, this chair is being cradled in a hammock.  A fibreglass hammock. 

Like a newborn baby, this chair is being cradled in a hammock.  A fibreglass hammock. 

June 5, 2011
More sanding and we’re getting closer.

More sanding and we’re getting closer.

June 3, 2011
And after sanding for hours, you begin to have a table.

And after sanding for hours, you begin to have a table.

June 3, 2011
Wondering why there hasn’t been much in the way of updates lately? I’ve been working away making a second Gull Wing Table for a client…by hand.  The original was milled with a CNC router, but this one is being done by jigsaw and belt sander.  The leather project and concrete work will have to wait another week.

Wondering why there hasn’t been much in the way of updates lately? I’ve been working away making a second Gull Wing Table for a client…by hand.  The original was milled with a CNC router, but this one is being done by jigsaw and belt sander.  The leather project and concrete work will have to wait another week.

March 1, 2011
All full of concrete.  This is a deception though: even though I’m posting this before photos of the table out of the mold, it’s actually my second pour.

All full of concrete.  This is a deception though: even though I’m posting this before photos of the table out of the mold, it’s actually my second pour.

February 27, 2011
Gettin jiggy with it!

Gettin jiggy with it!

February 18, 2011
Have no fear, the table top blank is here!

Have no fear, the table top blank is here!

11:34am  |   URL: http://tmblr.co/Z60nSy38cpCn
  
Filed under: epoxy mold process design 
December 30, 2010
But alas, here is the mould all full of epoxy gooeyness.  Nom nom nom.

But alas, here is the mould all full of epoxy gooeyness.  Nom nom nom.

4:43pm  |   URL: http://tmblr.co/Z60nSy2N14i9
  
Filed under: concrete epoxy mould mold process 
December 30, 2010
You have to be careful not to make too wet of a epoxy mix, or you’ll end up cursing and pulling it all out by hand so you can add more aggregate.  I noticed that the pva was becoming a bit slippery though (meaning it was being dissolved), which concerned me that the epoxy was bonding with the mould.  We shall see tonight!

You have to be careful not to make too wet of a epoxy mix, or you’ll end up cursing and pulling it all out by hand so you can add more aggregate.  I noticed that the pva was becoming a bit slippery though (meaning it was being dissolved), which concerned me that the epoxy was bonding with the mould.  We shall see tonight!

December 30, 2010
This may be the last shot of the mould looking this clean… ever.  Lets hope those layers of wax and poly vinyl alcohol work their magic!

This may be the last shot of the mould looking this clean… ever. Lets hope those layers of wax and poly vinyl alcohol work their magic!