The wooden frame is now coated in fibreglass and sanded to create the plug which in turn makes the finished mould, this process will take approximately 3-4 days. This is a third of the overall tree ring so it’s no small task.
Now that the plug is complete we begin to cover the plug in a fibreglass shell [the red ends in the first image are the beginnings of the mould]. Once the new fibreglass top/shell is completed a frame is built around the mould so it can be inverted, then the plug can be removed from the mould using the crane.
During this process the plug will usually end up slightly damaged, but now if we ever have to make another plug we can do so by working back from the mould.
Stay tuned for the final stage and where will join together the 3 pieces which will make the complete tree ring.
Today at Quatro we are making a mould for a 4m dia tree ring with bench seat and thought we’d like to share some photos of the process involved in making something that in theory seems so simple.
The timber frames used to make the mould are one of the most time consuming processes in the overall construction of the product, using tecninques heralding back to old barrel making or clinker boat building. The mould is painstaking built in timber first, screwed & glued, [the stage that you see here] then the thousands of screws used to build something of this size are taken out and the holes bogged & filled. Overall this first stage of the mould making process will take approximately a week. This old fashioned technique is favoured by us for various reasons but another way of producing a mould like this would be cutting a CNC 3D mould in foam. A dying art? Stay tuned for the next stage!