LIVRO MODELS & PROTOTYPES...[página 103 a 132]

Prévia do material em texto

/D Dmw a mled lille lar Iile J<·sIIiZPed position on 
lhe IIpper "ec/io n. 
j.~1*o)Jb:; "JJS:U:ftJ.tJ\ 0&:\~-;j$O)T I 'Y 
?~~.Qo 
• Jllhile sllIdying lhe enlire balance. check lhe 
rCfluired mCaSI{remen ts. 
" Use a rough bladed sal<' lo CIII 011 ai lhe base 
clllling posilion. 
703 
fl) Creale Ifte spolIl. Dra/c Ifte lI1eaSllrements lI'i lft 
a mler 011 Ifte re/'ealed easl core. 
I@)~~U «,) ~ iít!Oijü[§jO)):Jt! ~ t':9 o 
f1) Slwve around lhe exlernal , Iwpe while occa­ @lThe boring_ 
, ional/y confirming lhe , lia/lc. Produce lhe thickness of lhe spout edge. 
f1jPre/Ja re a /Jallem lo shave ou l lhe concaL'e 
sha/Je, 
W6~~~<~o*~U~~[§j0)~-~~~~ 
~< ~o ;c;tl:lut!nt.::D.fIl~I;:6~Wi[§j0)1/ 
291-ff~~Q!J~ (iII!~) C:: U L:"~jUI:Ji6t;t.:~'f$6 
~~9~o 
fl9 Mak. lhe Izand/e. Firsll)', malce li in a dough­
n/ll slwpe lUilh a U-slzaped aos.,-seclion. 
T!lke lhe measureml' nls of lhe revealed core on 
lhe casl cylinder in arder lo carve lhe concave 
slza/Je as a half-size of lhe exlernal sha/Je for lhe 
cross-secliol/ of lhe Iwndle. 
704 
I/nserl lhe cul/ing line on lhe bol/om base 
.~ ('/ion and use Ih~ edge bLade of a pLane lo cul 
Illmmgh. 
(jUs a Lalhe lo shave oul lhe cone'ave shape 
whiL" continuollsLy confinning lhe paliem. 
a>~l!l!~J (jJl):011fv) ~/\l/'Y r..T17C'g 
~~.~~~. ~n~~~M~. :O~fvH~~ 
<~o 
f1)Transfer some polosh soap in lo a conlainer 
wilh a knife and add some rualer lo make liquid 
soap. 
~Cul oul lhe s{Joul from lhe casl on lhe poller' 
s wheel. 
~~im~i±J:11(!!]OOO)(fj~l!l!~JO)jJ 1):011fvH 
~~-I;:~~o 
~CompLele lhe slIrface and ap/JLy even coais of 
lhe polash soap only lo ti/e concaue seclion. 
~*~~:O~fv~~*~.fv~~~YvC'~a 
~~o 2 - 3 @]*i~~9o 
ID Wipe off lhe excess liquid soap ruilh a damp 
s{Jonge. Repeal Ihis process Iwo lJ1' Ihree limes. 
705 
--
- --- --
fJ Mark lhe posililln Ihal will become lhe cenler 
smface 01 lhe h.andle. 
- - - ..-­
~~~€a~~~~~~~~.€~5~5~~ 
t:~ (tO.5mm) L'fIl~€J<~. ~.;IE!m~;m 
G~t;o 
~Make a cylinder wilh a vinyl cMoride sheel (O. 
5mm Ihick) lo enclose lhe casl. 01 which lhe 
exlunal roundness has been shaved inlo a COIl· 
cave shape, and paul' some casl slip in lO it. 
leDrall' a dllllgllllll l slwpe inside diameler. 
~~ê$~t(7)CPJ[,\ 
rDJ-:J -ci\! 1J ~"f(1.Qo 
0 Shave down lhe inner diameler lowards lhe 
cenler (marked posilion). 
706 
Ilfli1::l;:jftf ui6*tL1:::O.o)~W~1:J' 6...t1J1;: 6')1fX~~*~fIlfqíI'J:I!jU ~rFI1. -i-0)1~UimI'J:U"FI12~C-g$l'J:fm<o ff~ I;: i!WJ i6 <t o 
"Dratv in measuremenl /ines lar lhe widlh 01 
lhe halldle on lhe seelion above lhe boundary Ime ~Shave down lhe eylinder lo lhe widlh 01 lhe 
01 lhe lIewly poured casl. handle and sJuwe oul lhe side:; inlo a U·:;hIlPe. r 
~~iml;:g< -!f/ t-:"'-J'\- (#240) 1'J:1:J'lt-Qo 
~~~2~. U~.imt-:-~~~O)tt...t~Oo 
~Lighlly rub lhe sm/aee wilh sandPaper (~240). 
CompLele lhe doughnul shape U.shape cros'\"·cul 
wilh a Ihickness 01 abotll 2mm. 
~(!!]~ (1Iut~) ~-:)ltt.:~QjclB.lff~o)CJff~~~ 
I'J:jÃJllIYI;:-:)lt-Qo 
~Give a convex shape rollndness lO lhe. inner 
pari whieh is lhe same as lhe roundness glven lo 
lhe concove shapes. 
707 
I(DRemove lhe core Irom lhe main cosI. 
~ft<~s~~~~u~~~~-~~m~~0 
:o.iItt~1:J\SIcl:9'n~o 
eThe U-shaped cross·cul doughnul shape wiU 
come 011 Irom lhe lower concave casl by lil ling 
gOllly. 
$Fix lhe posi/ion lar lhe ~poul. DriU a hole wilh (fjFix lhe spoul lo lhe body wilh an epoxy resin 
a joggle. adhesive. 
708 
leAdd a slope lo lhe main body. 
f)lv!ake a Plallorm on lhe ,paul and shave fi lolecuI lhe botlom ba:se diagonally. IG)Cul an opening ai lhe lop. lil lhe body. 
-=-~ =-=-- -.,- -- - - - -=- - -- -=--==-=--::::::--- - --- ----=- ' -- ­
__1_- __ _ _ _ _ _ _ __ _ _ _ 
fiFix lhe size 01 lhe handle Irom lhe U:shaped 
cross·cul doughnul shape. 
-~~-
IGlCul wilh a saw. 
709 
1 ~*~~TOatt~~~~~D~~.g~~~ T.Qo 
ft S /uwe il lo fil I/I e body and fix it with an 
adhesi/le in lhe same slyle as lhe !'pout. 
I ({J) Complelion. 
I~Compteli()n. 
770 
Cut/ery 
? L.-1 'ET) [; -> 75 À $'-'ET)[; 
:tJ ~51)-0)W'l. ~yO)~~. ~0)l.ê0. El 'E~)\/ ~) [;O)~'I) ':'; 
:1~Ij:. ~~C~(;::~tJ!tL L # Llj: vOf)L*?J 1~O)l \< jj~tJl1~~tL80 
SSâ:tJ'1d:tI\l) .:J. - L~? l/1 c'~O)çpC':J <0 L 118. i1&~1>tJ: 
R~0)~1~~úf~ Ij:. E.Cd3~tJ' x. L~~;j980 
~ :1-/. 7~-? ~170)~~~W'l~~m. E.C':J<8~ 
c:'::1J"C'~8tJ1~FmU~N:f!l C'l.gtL~gl \0)C''Y I) :::J /1Iiff~tJ\~E. 
mjj~~~~jz~Villv. ~~1>tJ:~8;j1;::®L 8~J;l \0 
C/ay mode/-- Piaste r model 
1I is impossibie to become salisfied wi/h slwpes ",ilh regards lo lhe Ilill1dles 
of f ullery, doors, sauapans and biLycle grips //nlil Ihey are ac/ually fell 
wi/h Ilze hands and Iried 0 //1 , 
Tile rough volume {"ill be aealed lo slwpe wi/h lhe IIse of ciay and lhe 
hands, The delh'ale change and ha rdness of llle sl/(/pes !I'ill be sludied 
in place of lhe plasta. 
The lop paris of splllm s.forks Imd kniues can be made wilh plasler ill lhe 
s({me way as lh e Iwndles, blll il is advisable lo prepare mfll'ly differenllypes 
from concave ";fico,,e slla!)e" lo rough plasler shapes in orda lo apply 
a delicale s/udy of Ihese fragile objeds. 
:;']1--5') ­
~~/~À. 75À~~?maM~~~~~5~-. À~T~À~~~ 
Cullery A sludy ske fch of cullery mode from a combina lion of male ria ls 
of sla in/ess slee/ and p/aslie. 
777 
--
O~~?~~~Bro~~~~. ~~7~ ~ ~T 
~*~~. m~?~~~~~~~T~o 
O Use clay lo sludy lhe size alld slw.pe which wiU 
fil lhe dille-renl gn·p Iw.ndles. 
0~~r~~r~IU1~.~L\Mj~. ~l~ro/\?:;Àt 
~~;jT~o 
0 G,:ve a I"rlher sludy lo lhe enlire bala /Ice b)' 
holding Ih em in lhe hands. 
0T-7)I;..t~ro~)Eut.::~~BroI7ç~~r~ 
1JO;t~o 
0 Add some work lo lhe handles lo make Ihem 
slable when tI,ey are Placed on lhe lable. 
8~~~~7-~. 7~-? ~~7rom~~1 <o 
8Draw lhe shape 01 lhe spoon, lork and knije 011 
Ihick pape,.. 
- - ... -- ---~~-='---:-
O~7-~. 7~-? ~~7ro~m&U~~ 
im~m~-:)< ~o 
fj Make lh e paliem.> lo r lhe exlernal slw.pes 01 
lhe spoon, lork and kmfe and lheir chiei cross 
cul pallerns. 
7 72 
- -
CH·tt61,ttlJIJIIXIJ . tlTlJatll:f<t:><t:>*n'1J:1')l. 
-V1,t"J~o 
8 Cul Ihem oul and lold Ihem lo rnake rough 
;mLIges. 
O~~1'0M~~.0~7-Y. 7 ~-~. ~ 
1'71,t-::Jltc:: cfj.~ o 
OA I/ach lhe spovn.lvrl, (lnd Imile, made oll/lid, 
paper, lo lhe clay l/andhs, 
- --.- - - - - - ~~~ 
O.lIXlJ~n~~91'D7~-bEK~~.~ 
iiliirmT-7~H<12I~"9.Qo 
OLighlly lix lhe pallerns onlo lhe roughly cIII· 
0111 slyroloam EK with dOllble -sided adhesive 
lape, 
0~.~~?C::~91'07~-b~~-~~~ 
9-(7D7~-b~~9-)C'tlJl)lIX~ 
0 Use a ileal-culler (ProloTnI cu/ler) lo cul lhe 
slyrolomn along lhe pal/erns, 
.~~m. ~mmW0@~~~~-~~~9-
0=~Db~~JJt0~f~cT-7)v..tI;:@!Zifl!l 
1,t I~"9 .Q ~Ccj,UIX I) n'C'~.Qo 
IIDRough shapes oi Iile body rel 'olulion, cylindn'­
cal ar cone shape-" can be aâúi'I'ed by changillg 
lhe angles 01 II, e nichrome l-I'iYl' 01 lhe heal 
cullel' and placing a rolar.' -,11011 on Ille {able, 
773 
ID? l..I~ Wi~~:1jI: ~ ~~ o 7 ~ - bm~OI: 
À~~::>11-?> o 
f) Round lh e rougMy cul slyrofoam wlzi/e using 
lhe elay lumdle as rz reference. 
1 ~~ 7-YW~~~D7~-bm~o~~-~ 
jJ ';J ~- (~-~=- I' )v~) ~[!!]im~::>11-?>o 
4f) Cive rz concave surfrzce lo lhe roughly cul 0111 
slyrofoam spoon lVilh lhe heal culler (heal needle 
Iype). 
e:; I) :J YfifH~~ (~~c:::~ igl:J:? n~it~ 
~~~~~) ~~~ D7~-bm~~~O~G 
:;~:JYa~~im~~tt~~~~5o 
4DJil:G i6fvtêE.ilEYJ1J.tJ'J>-GfifitGId:Lió".l1::;:-3. 
I'\, 5~*?ttJE.~~OIl*~~im~~;t~á3<o 
«!J Remove lh e excess casl tuilh a ,palula IIsed lo 
Ireal surfaces when lhe casl sliP beaills lo IUlrden. 
CD Take 01,1 Ih,' roug li slyrofoam shapes from lhe 
fnilnes afieI' lhe si/ícone has Iwrdened (The lime 
réll" ired for hllrdeJ/iJ/g will difler in accordance 
wi/II IlIe cata1ytic agenl used and lhe 100m tempera­
lure) alld (('ash lhe concave silicone mold wilh a 
I/clllra/waslúng powder. 
fi :; I):J Ya~I:E.iFt; !IJHi'F 0 15Id:No. 4~~) 
~Jil: Gi6<tJo 
fl Pour lhe casl slip (See NO.4 for dire clions on 
making) inlo lhe concave silicone molds. 
774 
I_À7-Y, 7~-?, T~7c~, ã~0À 
$7~D7~-b, jfiJl~I;:VI';;'.) (IJ~T';;?1 À) ~~IJ, ~im~~;t~o 
~À9~D7~-bmm~~~.mm~m~~ 
~k~À9~D7~-b~~~~IJ~Y~~~ 
~<~o~~lJm~IJ~Y~~~~~.OO(~ 
1&L'~8F.1.~~:15) m~9~o 
4IICreale a com'ave silicone paliem, lIsing lhe 
slyr%am as a paliem, in arder lo produce plural 
number 0/ rough casl shapes /mm lhe slyr%am 
shapes. 
Add a calalylie agenl lo lhe silieone solul;oll lo 
make lhe molds (read lhe imlruelions) and stir. 
~À9~D7~-bmm~~~~~m~, ~IJ 
~Y~~~<'o 
(JPrepare lhe pour-r!n mold frames for lhe I'ot/{?h 
slyrofoam shapes and pour in lhe silicone solu­
lion . 
• ~'-I\fi!ilj~, ~IJ~Y~~f.J\~~, À7-Y, 
7~-?, T~70~.mm~~~9~o 
eTake oul lhe rough casl shapes of lhe spoon, 
fork and kllife afler Ihey begin lo ge nerale heal 
and beeome hard. 
Wj!jUlJiM;i-il~ifJ\'JI-~ 3 Y~;t~k~, ~ 
IJ~Y~~~~m~0~.mm~~~~~~<o 
flDMake several rough casl silapes in lhe silicone 
molds in arder lo gel various sltauirzgs. 
l.4dd some coais 0/ j esso (Liquile.x) lo each 
rO/lgh slyr%am spoon, /ork and kni/e including 
lhe handiEs lo Ireal lhe surfaces. 
7 75 
~~n~n0~.mm0~~~~~~~~ (. 
JlmmEl) C'~9 o 
. Cul away lhe unnecessary paris on each rOl/gh f1)Shave Ih em inlo shape, using lhe saw blade, 
casl wilh a sow (rough bkuJe for mElalwork use). whilsl conlinuously confirming lhe shapes . 
• Use lhe some process on lhe rough cosi handle 
lo complele. 
~ Use a ioggle lo drill a hoLe (2mm diame­
ler) for lhe joinling. 
7 76 
@l;@~L,1::1 ><-:,n:JWJibfvt.:~. 'mEl1.J'b 
M1E10}!fY ~"-J\-~f±...t11~o 
I~The compleled S/Joon. 
.Use a range oi sandpaper Irom rough lo fine 
grain lo complele afier Ihey have been shaved 
il110 lhe image shapes. 
8À?-Y. 7~-? T170~$cm$~ 
!l.~J (I~:f:;*) ~[§J:lE9~o 
IFix lhe head parts oi lhe S/Joon, lork and knile 
lo lhe handle paris wilh an adhesive agenl (epoxy
re5Ín). 
WÀ7-Y. 7~-? T17tn~n0~$ 
mªI:: '7-:;') [.d::t§l:Jij!L, t,,n \J:5m$riHi:tJ 'Y 
r-0~!m~9~o 
GilAdd small adjuslmenls lo lhe surfaces oi lhe 
handles lacing downwards when lhey are on lhe 
lable lo preveni lhe head paris oi lhe S/Joon, lork 
and knile Irom directly coming inlo contacl wilh 
lhe lable. 
7 77 
tl)=F1;:~t)~0)~t)~g-. ~L\Mi=F1ct&itVL<b 
I.Qo 
fl)Hold lhem lo see il Ihey {Ire comlorlable lo 
{{ril) and use. 
GlColor lhe haudles {md sludy lhe material 
di((erences Irom lhe head paris. 
7 78 
Ir~57:7' 
80th tuh 
"1:7 1) ~~l~lIX~ 
Modeling orrangemenl plon 
15À7-'/?"7 71" -b.-'E7')[,,-> 75 À 5'--'E7')[" 
~~~~, ~, ~-o-, À~~~À, FRP~§~~M~~~ 
:bn-c: e\-8 0 
== C'lct, i&lliJ: <me \Sn-8Ai§*J~~;tH.!!io)7'+j· -1 ~~ ~-c: 
#?J o 
~~15À7-~?~~~~-c:~~~n-8~m~75À7-~?~~ 
• I:S~1J'x.tU;:f'-'ET·lj >~:J':t~~~~fJ)~, ~o)iM*'J:til5S 
t.J' l/õt)i';~IJ c'~-8o 
8=1 /5-'E7')["c'lct, ~~O)~g~~[J~C'À5'T·.{, t-nl::::~ ~ 
t.J'lj, C'~t.::mM;tl~~~~1~tJ1J'\S~U0i6to 
J'í.À5'7 
2AfflJ\À 5'7'0)~~ff~I)-fj--T, 
80th tub 
Amemo skelch 0/ lhe research on lhe basic shape 
oi 11 ba/h /lIb 
P/ostie foom mode/~ P/oster mode/ 
Many differen/ ma/criaIs such a.s wood, enamel, s/ainless s/eel and F. 
R.P. are used for balh /ubs. 
Here I wiU demonslra.le how lo design an arlificial marble balh 
lub whieh is lhe lalesl fashion. 
This lub is produced by pouring plaslie inlo a mold. If lhe plaslie is 
replaeed wilh a plasle?' em;l, lhe rnodel will be similar lo lhe produe­
lion model. Therefore, lhe reslrielions of rnassproduclion ean be 
anlicipaled beforehand . 
We wil! sllldy lhe eoncave pari of lhe balh lub made in a eonvex 
rnold on a scale of 1/5, and Ihen pour eas! in!o il and shave lhe 
rough shape of lhe balh. 
7 79 
0./\1*"'1$1J'6;fi~o)S = 1/5!i!;I/;:"'1$~~d::>;: 
ro~go)~ffi~o)E~~b~~H~~~, ~ 
~~ffi~~go)~~-V.~~fi5 o ~~~. 
~~~~D7~-bEKO)m6~~r~o 
0:a-.~1J' I:tt.:W.i, ~rfl;:::::a-.1J'~~ ~â:tcJ:L. \ 
J:5? Ld~ll*rE\l~5~~o 
0 Block Ilte opcn edgcs ai lhe bol!om of lhe mold 
{('ilh ela)' lo prel'cn l penelra"on of lhe casl when 
i I is POli red. 
o Work oI/I lhe basic 1ncaSl/runenls on a 1/ 5 
,caie for lhe balh lI/h by measl/ ring a person lo 
elral<' lhe /l/an. 
We tuili slllel)' lhe image of lhe IlIb pari from lhe 
C01zvex sha/lc in Iclticll Ilte reuerse CO l1caw shape 
of Ilte balh II/b lI 'ill become as Ilte carvillg of a 
cancaue slwpe tuill prove loa dUJicult. 
Willl lhe Plan as a paliem, CI/I ou l a rOl/giz Piece 
of sl)'rofoam EK. 
f)~HU::::I~H.lffl!m~~tcJ:L.\~1!f, x:f7--J\-, 
:J-TR (:p-)[;) tcJ:c:015IJ1LJcJ:1J'6E~~b 
~ ~-V~il~ I;::::GLL.\<o 
f) Whilsl considering basic condilions lhal can· 
nol be ignored, stlch as lhe laper and R·shape 
areas. fashion a shape inlo lhe shaving image. 
fj Build up a pour·on mold frame around lhe 
mold lo gel lhe Ihickness and shape of lhe fringe 
pari of lhe balh lub. 
720 
l o~~oo. :::J-T-RO)i±...tlj~9~o 
IC)Allach lhe proce.<sed paris lo lhe lub. OAdd a final louch lo lhe joinls and lhe comer R·shape. 
(J)Make a frame for lhe casl slip wi/h a slyrelle 
board. 
0~~OO0)8~~G~.~~0)~n~~75~ 
Vffil[!!]~O)C'~...tOo 
o The casl slip is poured inlo lhe fringe jJarl 
Ihrough lh e conuex shaped ballz lub lo complele a 
concaue m old. 
727 
- - -- - - - - - -
~~~~(~~~~~~) ~.~~~o~~~ 
V~&~~~O ~n~2-3~~O~ro 
4D Wipe lhe slIrlacu cleal/ willi a ,ponge soaked in 
polash liqllid soap. RejJeal Ihis pl'ocess Iwo OI' 
Ih ree limes. 
~~.~.~~o~~tt~~~~.~*~~. 
~r;:-im01:J\ rj~o 
(JJMoke some casl slip alld pOlir il over lhe 
surfnce 01 lhe mold ai lirsl. 
~~~~<~O~G~~~.~.~~~~O~ 
r1~o 
~Build lIP lhe m:;1 slip which Iuzs slarled lo 
harden on lhe mold. 
- - -----------= - = - ~- --- --- -- - - - - -- - ~-- ­
• The 1/5 senle roI/giz [{/.SI 01 lhe bolh lub is 
I/OW com/Jlele. 
~75~V~~~1X-V~~51D7~-~ 
~~5~~. ~~~a~tt~.~r~o 
~Sludy lhe image 01 lhe Iringe pari made oi 
slyroloam lo eheck Ihal il mnlches lhe bolh II/b. 
722 
I'I Remoue lhe convex pari 01 ti/c s/yroloam. 
1 .:O.;IE!mt.HUI!~11:;1l. ~ttfm1J: leigo uJm~ 9~o 
. Afler lhe casl slip has begun lo generale heal 
alld I/{/I'dell, remove il from lhe frame. 
image onlo lhe 
I «il Cive ir a rough slla ve. 
723 
I mThe 1/5 scale casl balh lub is now complele. 
WjiH3tJ'6K:!E130ij-Y !'-"'-J'\-L'K:!EOO, ~im 
0f±..t111J:fi5o 
fd!) Use sandpaper ranging Irom rough grain lo 
line grain lo comPlele lhe delails and surface. 
I~Shave 011 lhe roundness. 
724 
Ver,ide type 
Eove guHer 
(J) ~ :':'"IfliN/)'ck -3 c: 
Eave gutter 
?l.;1~Tlv->-:J5À 5'-~Tlv 
/1"111;?~-{ eltl±) 1,t~O-::>ltt.::O, ~IJOIlY.-::>t.::O LAJ1:J~ S, 
ll!lL \0)**0')ff~j;:::~1t~ttL l, \ <, 2 ;~B:lliID, 3 ;~ElEiIDtJ2:'O)Êl 
1ffillllimO)i§1f~I::::? ~-(Id:, g-lcf'S LA \TT ) :,;?'M;jG.jC'3)8o =j" 
111 :;i§1f~ffi? ~-( C G n!~O)-{ :,; 51'À 1--1) ylv? ~-( '1:,3)0, 
/1"-:1:,;c;~~, ~OLI), 1±LI1f.::frt~[ID9[l.I~'I:, C~80 ;:;: 
z.'1d:~ < g~O);t-{ lv? ~-( 1,tiie -::> L JL~ff~ffio) LJ ~"3 C1,tT 
if1:;GLet;.8o 
t~.~1,tOO~~?~-{~m~s~.O).~1,t~;:G, ~S.~ 
I;:D.;IE~1,t;m Gi6et;.? ~-(~~1,t~. I::::<I3~1:J\~ 8 0 
;:O)~TTll,;c§W~, JJ.tR~~~O)~~"'P, ~~JJ.tR~IflO)~c G 
"[O);õffi'l:, C~8o 
Eave guHer 
Mode/ing orrangement p/on 
725 
Clay mode/-+plaster model 
Clay is a wonderful male1ial for modeling any lwo ·degree or lhree· 
degree surfaces as sunken areas can be refilled wilh oil·base clay, and 
shaving inlo any desired sJuzpe is possible. 
For design modeling, a Juzrd type of industnal clay is available on 
the market. This clay can be healed in an oven to make il nse and 
will easily lake surface lrealment afler lhe model is complele, 
Here 1 am going to design a round·shaped eave guller using ordinary 
oil·based clay, 
Make a concave cast mold from the well·studied onginal cla)'pallern 
and pour casl slip into it to replace the onginal c/ay pattern wilh 
cast, 
With this cast model one can study color, plaslic ingol molds and 
also the use of the mold for vacuum foaming. 
fft1L.í~"3c 
A~fi~ffl~~5c1~-V, ~~À~~~ 
lmage skelches of fi YOllnded eaue gllller. 
\ ) J ~ 1- -
~ 
8~-~~ ~ 9- (7D7~-b~~9-) ~ 
W~~k~9~D7~-b7D~~~~~~­
7~1§l:lE9 .Qo 
fjFix lhe slyroloam block. ",hicil lUas clI l oulwi/h 
a heal culler (Pr%rm ClIl1er). wilh double· sided 
adlzesil'L lapc. 
O~lIl!'HiM. t~~~C:(7) i!m~~~G1d:tJ' 6. 
~ )( -V~ ~(. \.Qv J: '3 ~J; IJIJ\<!~(7)~ I.d 
~~~9~D7~-bEK~J < .Q o 
o Use slyroloam t'K lo make a elay core which 
should be smaller /lum Ille design image guller, 
",Júle laking Inlo consideralio" lhe conneclion lo 
lhe rOllnded eaue guller and verlicle waler pipe. 
I ~VJ:'3~~~L~ttkif.(7)~9~D7~­
,b(7)~ l,,-~~tJ"'~·~.Q o 
ê A slyroloam elay core lacing wilh lhe lunnel 
on topo 
OvJ:'3~...tR(7)R CP-Iv) fgltlcl:7'5J'\Y 
(tl .Omm) C:Ij-V ( lIl!~) ~J< 1J7I'~ )v~ 
l,,-~~!I~C:.Q o 
8 Use Plaban (I. Omm llzickness) lo make a gauge 
lo r lhe R·shape 011 lhe upper edge 01 lhe lunne/ 
Gl1d remove lhe oil·based elay wilh il. 
071'~ )v~ l,,- ~ mHIl1(7)~~...tlJo ~(7)-ffilRtl:J 
~kffil~~ft~&Uk~~c:~a9.Qo 
oThe comple/ed oil·based elay lonn. The jJarls 
revealing lhe core are going lo be joined lo lhe 
eave guller and lhe vertical lUaler pipe. 
(l)~~ ~t.:::ff~tJ'~~nlcfm( ~~)~" '5 (7'5 
J'i.Y tl . Omm~fi.q(7)ff~ifl;::W::>kt(7)) L' 7I'~ 
)v~ I.d~~~~6tJ'I;::9.Qo 
(j)Using haúng spalulas (variolls shapes cul lrom 
lhe 1.0mm Ihiclmess 01 Plaban), make lhe oil· 
based elay surlace smoolh once lhe design shape IS 
compleled. 
126 
~~~~----~~----------IIII~------------------------­
O~ I:::7t~Jv?Ld (;!E±) nl J:. < (J)IJ. ~t.::. 
;Z~~07~-b'fAnl? Ldl:::~ÃGtJ:L\J:.5 
.~~VI~~ (~~~~?;Z ) ~~.Qo 
O ApPly a coai oi Jesso (Liquilex) lo make iI easy 
101' lhe oil-based clay lo adltere and prccenl lhe 
slyroloam powde!' Irom gelling mixed wilh lhe 
clay. 
0~JUi"l j;:: I:::c -::Jt.:7t~JV?V~ Oll±) ~fljlG 
Jlt.QJ:.5I:::~I:::mi IJ f'1lt.Qo 
o Take Ol/I a Ih/./mb-sized piece oi oil-based clay 
and pres~ il into lhe core lo build il up . 
• ~ÍI 'V ~n\~L \t.::':':O.~l&lJffl75;Z7 'V 
1~tt2~)~;Z~~07~-b~~~~~­
:::1"L'~5:E9" .Qo 
eOl/ce lhe Jesso dnes, lix lhe slyroloam core lo 
lhe plaslic sheel (2mm Ihick) lar making lhe casl 
mold /Ui/h double-sided adhesive lape, 
-~ ~-:-=- -.--=----=- -- y--~----- ---.-- ---- ---- .. ~- - --­--~----­
- ---~ - - -­
1'1 v~mHr;!tJ\':':O.iI!ji~~I&.Qt.::dJ.~~J (jJ 
1):O:ltfv~) ~.~I:::~IJ. 7./<~'Bfvt::;Z*:'-­
VL',3\~c.Qo ;:n~ 2 - 3 @]kilJi!&9"o 
eApply some coais oi polash liqttid soap lo lhe 
,urlace il/ arder lo make il easy lo remove Irom 
lhe cal/cave casl mold aud wijJe ali lhe excess 
lI'ilh a damp sponge. Repeal Ihis process Iwo OI' 
Ihree limes. 
fDBuild up a pour·on lrame wilh a slyrene board 
(Smm Ihick), 
727 
slip over lhe surlace 01 Ih" 
~tJ\I:tt.::O. ilE!ml;: ~ LAti fJ WC'I<l: üIS'Jt.:;:-3 
~5~~~~~~~-~~~~~~~5~fJ~ 
11~o 
4Il0nce lhe casl slip becomes a lillle slicky in 
consislency. use a spalula lo slroke it lo an even 
Ihickness ali around, 
871'1' Jv? [.,.1' JjjHll!~iID1,!:jj!J0tJ\I;:1±..t11t.::J 
=t. fJ ~=t.:O.~H;:&:tfi9~ c~1).c ~CJ L" "C l \ 
~o ~§o)if::; ~"'-J\-~p;jiID1,!:~ 01;:1±..t 
11~o 
eTlte ('(~~I rnold mighl hove some areas on lhe 
sl/ rlace wltich are wauy. de"pile lhe smoolh sur­
lace 01 lhe original form , Use a piece 01 line 
grail'/ed sandpaper lo give a yel anolher linal 
10l/ch lo lhe inl/er s/lrlace, 
tEl:O.iUHI~I;::O.ilE!m 1,!: ~ L"iM, C !Il1t;0)~. 
:O.fi~•• a~~~~fiÀ~o*~1,!:~/:J)y 
~~9~t.:IS'J~0~üIS'Ja~~W§1,!:Àn~ 
~~~0~~@. ~~fJ1,!:9~~a. W~~­
J\-1,!:-t71I;:~fJ~~I;:;Z$7';J7 (m;*l 1,!:ilE 
t!'ffli~9~o *-t.:. ~1*tJ\~L"l\~al<l:;:;lj:::J 
::; a~1,!:fUIfj9~o 
4IlDun'ng lhe process 01 hordening aller lhe casl 
slip has been poured into lhe concave cosi shape. 
lhe case will expand and crack lhe concave mold. 
In arder lo remove lhe rnain unil wilhoul any 
damage. inseri a cul onlo lhe concaue rrwld 
belorehond. When more lium one mold is needed 
lo remove lhe concave moldo use a sulfide,,1 
amounl 01 lapenrlg and mix resin inlo lhe con· 
cave mold lo ,-einforce ils sl,'englh, 
Use a siLicone concave mold when condiliom 
diclale i l lhe bel/a choice, 
728 
41)/1" -{ Iv? v-{ Jiji~I;::o. ;Ft~J,t~ttUf1t.9Q 
O)J,t*-::>o 
QlCol'er lhe original fonll of lhe oil-based ela)' 
wilh casl slip and wai! IInlil i l "ardens. 
leTfie cOr/cave casl moldo 
18:0 1ft:J\~~Uf1t.9fl,/;t/1" -{ 11/7 v-{ Jiji~t:J'6 
JI!t!f!9Qo 
.11'11<'11 lhe casl gene rales heal and hardens, 
I remove from lhe original oil-based clay formo 
IWPour lhe casl :;Ii/) il110 Ifle cOl1cave moldo 
,APP(\' a coai of polash liquid soap lo lhe SW'· 
/txe4 lhe illuer side of lhe cotl cave mold and 
rI/If 0// ali)' exce~.' wilh a damp sPonge. Repeal 
IIIis process Iwn OI' Ihree limes. 
729 
~~~~~~:O.~~~~Dn~~~~~~~, 
1Jc!t.N~-I;:1J~J:?, ~5~mí~...t111f.1!.z~o 
fa When lhe crls'l ,li!, begin lo become slighlty 
slicky in consislcJ/[J. {(Si' a s!Jalula lo spread il lo 
an euen Ilúckness ali o ver. 
fDlIIllI'4!&iml;::O.;JB~t.H \~pt':QcI:: ?1IIl~~ 
~1:tQo 
fJ)Tilt lhe mo/d lo spread Ille slip euen/y OL'er lhe 
suy/ace 0/ lhe cOl/w/Je mo/do . 
~~~G~b~~~*~1J:O.~~TY~~~ 
"T-Jv~mí~SC9o 
~Use a slain less·slee/ sca/e lo scrape 0// lhe 
excess cas to 
I f)Nl'1II0 ll<' lile maiu <,asl unil. 
tB~i§]~-!fY t''''-/'\- (#240-#400) ~ft< 
i±...t11~o 
fi Ceully rub Iile sl/lface /l 'ilh a piece 0/ sand· 
paper (belweel/ #240·#400) lo /i uisil . 
730 
~;mui6fvt::O.1N'it.u, mê l:!~t9.Q~uk, ;;jI; 
f*!1g1ll~0)1'~tJ::O.~ J :J]:J C'~U O;',§ C9"o 
fiB40re Ih" cosi complelely hardens rmd is 
rell/afed (rolll lhe mold, shave off ali unwanled fl) Cive li/e 1llOld 1/ "I(gl/ I /(//) lVilh a (modell 
Cilsl (rim; ti/e inner sides of lhe main unil wilh mal/e! and remove lhe ca,,1 from lhe mo/d lV/ Ih 
1/ .<f/;" blfU/C. 
fil e/ll lhe gu/ler opal/1Ig lo fil lhe rOUl/ded 
wa ler pipe /lnder lhe caves. 
131 
~Check lo ensllre Ihal lhe rollnded eave gutler 
fils nicely inlo place. 
CDThe main ",úl of lhe eave gul/er is now 
complele. 
lhe rounded 
732