Here’s my go at it. This started with @Julien and his Tips on making this wall light? project. I suggested a “pocket, pour, surface, flip and surface again” construction. It was an original lightbulb moment for me. Little did I know that this method is already in use by the cnc gurus around here. Would you call it simultaneous discovery or personal creative evolution? This was a proof-of-concept exercise that evolved into a challenge entry.
The process:
Pocket a “mold” in some wood, pour the epoxy, surface and dry-sand to 2000.
Rout a simple, deco-ish design in the resin.
Flip the piece and surface for the reveal. I was astonished that the idea became reality.
As a comparison test to the dry sanding, I wet-sanded to 2000 with an oil/wax blend. This might be the smoothest cedar resin-casting form in the southeast US, maybe the entire country.
At this point, the challenge was announced and I thought I might enter. I released the resin from captivity to use as a faceplate for a small box. I designed some box parts and milled them from 1/2" MDF. Just say no to the yellow MDF (it should be called something much worse, which I did several times throughout the process). It’s the worst combination of dust, fuzzies and tumbleweeds.
Assemble the box (glue and pin nails).
Sample some metallic finishes. At first, I was looking for a deco-style, smooth, brassy finish. But, I went with the one on the right and decided to leave it rough, like an unpolished gold casting.
Finish the box and install the resin faceplate.
When I show the wife, she says, “It looks like a candle box.”
I say, “It could be a countertop mail caddy.”
So, since she’s always right… it’s a candle box, now at home on the patio table, poolside.
There were many firsts for me on the project. Here are a few:
- challenge entry
- epoxy casting
- two-sided machining
- intentionally machining a material other than wood
- milling parts made to fit together
- “OMG! That static business is for real, when cutting epoxy resin, plastic, foam, etc…”
Plenty of room for improvement, but I am happy with the result and learned so much along the way. Thanks to the community moderators and all of the entrants and community users for the inspiration and guidance!