Ressurection (a work in progress).

[Hausamann]

I worked out where the ripple will located, and marked out the curvature with a DIY compass and a ball pen.
These curves are guides for cutting the stepped rings/curves for shaping the ripple. These need to be cut out with a jigsaw. It took most of the day to mark and cut these (30 curved saw cuts).

On the wooden compass stake I marked the various radii for each curve.

 

[Artyczar]

Looks like you got this. I'm loving your mind and am so happy to have you here. You make me feel a little lazy about my own ideas though.

 

[snoball]

Glad to see you have a dust mask there, be sure and use it when you are sanding also. BTW, it is going to take a moving dolly to move this thing when you are finished.

 

[Hausamann]

Looks like you got this. I'm loving your mind and am so happy to have you here. You make me feel a little lazy about my own ideas though.

Well, I wouldn't worry about feeling lazy because I am starting to think 'What have I got myself into here. This is a lot of hard work. I sure hope I don't waste it all by painting poorly'.

 

[Hausamann]

Glad to see you have a dust mask there, be sure and use it when you are sanding also. BTW, it is going to take a moving dolly to move this thing when you are finished.

Yeah, I've been thinking the same thing. I don't think it will be TOO heavy but it will require stronger wall paint hangers.

 

[Hausamann]

Before gluing the Masonite curves together I need to have a supportive plywood board. To cut down in weight, the board was only as wide as the ripple. This support will need to be reasonably flush with the underside of the chassis frame. Meaning, that the farme needs to have two sluts, as wide as the ripple, cut out on the top and bottom framework. So, the Masonite ripples need to hang over its supporting board and be flush with the outer dimenions of the chassis frame. . . I sure hope that made any sense, but if not, I hope the future photos will make this decription a bit clearer.

Marking and cutting out the ripple supporting board. The drawn lines are guides to where to glue the first widest curvatures.

Below I am gluing the curvatures to the board and started gluing the next smaller size curves on top.
I tried to glue two curvatures at one time but found it too difficult to keep the two exactly in place while applying weights on them. So, I had to settle with gluing one curvature at a time, giving one hour for the glue to 'fix' for each one. It is going to take a good 13 hours to glue these stepped pieces together.

Bottom of above photo shows the overhang of the curved support board.
I used a piece of board offcut, under the overlap for support while gluing.

 

[Hausamann]

 

[Hausamann]

Sanding off the edges is going to take a lot longer than I anticipated. Masonite, especially the old stuff I got, is quite hard.

I am getting there.

 

[snoball]

Good that you got the hard stuff because it is likely tempered Masonite. The untempered stuff feathers badly when sanding.

 

[Hausamann]

Well, enough is enough. I hope to never have to sand Masonite edges again! You know, when I started sanding the curvatures it didn't seem that the job would take too long at all. But the more the edges got blunted the more surface area there was to sand. Over the last hour or two of sanding I didn't seem to be progressing much at all. I settled with about 98% smooth, for I knew that it would take many hours to complete the last 2%. Besides, I was sure the gesso and primer will fill in any fine unsanded corners.

Well, that's it for the time being. I am sore, tired and needing a break from this for a while.
The St Francis painting will be a welcoming change.