Replies

1. 
   ravenwind | Dec 10, 2003 07:00am | #1

   looks great, wow! nice idea   Dogboy

2. 
   BungalowJeff | Dec 10, 2003 09:28am | #2

   Very nice detail! The finished product is sharp.

   ...that's not a mistake, it's rustic

1. 
   donpapenburg | Dec 11, 2003 07:06am | #7

   Thanks for the compliments everybody.

3. 
   MojoMan | Dec 10, 2003 04:17pm | #3

   Fascinating! How did you make the mold? What did you use to bond the face to the block?

   Thanks!

   Al Mollitor, Sharon MA

1. 
   donpapenburg | Dec 11, 2003 06:49am | #5

   The mold was made of fiberglass for these blocks . I have since made up a pattern and had a castiron mold made .  I laid the face up in the mold and then set the block on top,while holding it firmly ,I flipped it over  tapped it and removed the mold. then cleaned up the edges.   I also made faces that I applied to an ICF foundation . There I used expanded mesh and a scratch coat . I set the block faces as soon as I coated the mesh . Back buttered the block face also.

4. 
   UncleDunc | Dec 10, 2003 08:08pm | #4

   They look just like the originals I've seen. Are the flowers also applied?

1. 
   donpapenburg | Dec 11, 2003 06:52am | #6

   The flowers are cast in a mold that I made  for the corner block . The mold for the block was taken from an antique original rock face block . I had about 8 of them .

   took the best of the bunch and covered it with aluminum foil and started laying up fiberglas.

   Edited 12/10/2003 10:58:46 PM ET by don

5. 
   tuffy | Feb 09, 2004 10:35am | #8

   That kicks ####!

   I once saw whole a set of the original Sears molds for those blocks go at an auction.  Molds for columns and everything.  Not something I could buy, alas.

6. 
   Davo304 | Feb 18, 2004 08:18am | #9

   Don,

   Looks fantastic....there's a niche here for you....start making molds and selling them. How much for a fiberglass copy of the cut stone mould and also make me a mould that copies that flower detail. Seriously...how much?   I'm definately interested.

   I'm fixing to tear off and rebuild my long, front porch this summer. Such a detail would really stand out.

   How thick did you make the faces and what type of cement mix did you use when pouring the moulds?

   I'm curious whether or not you could use a light weight mix of some sort and then attach it to an interior wall just like the fake stone manufacturers use. Heck, I'd rather use your "look" than what is presently being sold on the market.

   Let me know your thoughts...and your prices.

   Davo

1. 
   donpapenburg | Feb 19, 2004 04:09am | #10

   Davo ' I could make you a cast iron mold cheaper than a fiberglass one . I will have to check on the cost of casting ,it has been a few years since I had the molds made.

   The mix is 3:1 sand /portland or you could use a2:1 mix . I always end up with more portland any way. so it might be 2.75:1

   Thickness varies but about an average of 1/2 to 3/4"

   I put expanded mesh up on the wall ,scracth coat then back butter the cmu  and stick it up and strike the jouint.

   I'll have to get back with a price on the molds. I plan on going to the foundry soon.

1. 
   Davo304 | Mar 02, 2004 09:16am | #12

   Hi Don.

   I don't check this site every day...but I haven't forgotten you. Let me know the price.

   Thanks.

   Davo

1. 
   donpapenburg | Mar 10, 2004 03:01am | #13

   Davo , I got some UHMW poly today . I think it will make a better mold than FG or the cast iron . When I get my bill I'll let you know .

7. 
   JeffBuck | Feb 19, 2004 04:12am | #11

   wow ...

   great idea ...

   that looks fantastic.

   I'd pursue Davo's idea and see if ya can expand.

   Jeff

   Buck Construction   Pittsburgh,PA

        Artistry in Carpentry