We visited the Getty Center on PCH (the old Getty) and saw a wall that my step-son assisted in building many years ago. The wall was made to look like it had been poured in the early 1900s by putting weathered boards in strips across the face and shimmed out some at different thicknesses to make it accentuate the look. I loved it, and like the saying goes, STEAL IT!
To get the look, I got some rough fencing material from the big box hardware store, then ripped the 6" wide (actually 5 1/2 inches) into 1 3/4 inch strips. Each piece is shimmed slightly differently to gain the same effect as the inspirational wall. I made the form to hold two pieces. My thinking was that I could pour two as easily as one. With the total weight a bit over 250 lbs, so I could tip it over (photo 1) and I could manage each piece(about 100 lbs) to it's final resting place (photo 2) . One challenge was to keep the concrete from sticking to the form; soaking the wood thoroughly with a silicone spray did the trick.
My first attempt at producing an actual item was moderately successful (read: learning curve) and I don't love the terra-cotta color, but that's what I chose at the time. There is some crumbling, and I didn't shake the form sufficiently to get a great print everywhere. I believe I released the form too early. Even with Quick Set concrete, 16 hours is too soon.
I will try to improve on this as I reuse the form. I think it will need a piece of re-bar horizontally to provide more strength. I used chicken wire in each piece, but the moving of the pieces did crack each of them. This could also be due to the early release and my natural excitement. I will find a use for these for now, but for the large quantity I want to make (40+), I will have to improve the technique.
Basically I feel like a kid with a new toy. What great fun.
6/20/2010 ---
I've made five sets of molds so far, ten parts. The process has gone through a few improvements. I am using square drive screws to remove all the sides. The part just drops out.
You will notice that there are some color changes in the various pieces. That is due to the different types of concrete I have used. I found that the Crack Resistant Quikrete works the best. I like the color the best too.
Some of the issues shown here are: too much water in the mix (upper right); off brand concrete mix (left), and our cat being curious.
More to follow as the project completes...
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