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maandag 30 oktober 2017

New Tombstones, part 2

Allright, here's the second part of my new set of tombstones! In the first part, I talked about the construction and the new materials and techniques I used, in this part I'll talk about painting.


Materials
  • Liquid joint compound
  • House paint
  • Acrylic caulk (NOT silicone!)
  • Fine sand
  • Drill with mixing attachment
  • Brushes and sponges
  • Acrylic paints
Foam coatings
On my first stones, I used a mixture called Monster Mud, a mixture consisting of joint filler and paint, to coat the foam. Being the complete noob I was back then, I had no idea what type of joint filler was meant, and at first I tried mixing dry powdered joint compound with latex paint. Of course, this didn't work, and I found out you needed liquid filler. So I prepared small batches of powdered joint compound and water, and mixed my paint with that. This didn't have a long working time, about 30 minutes, and didn't have a good consistency, it contained lots of lumps. I then found out the stuff you need for this is actual liquid joint compound, not powder you have to mix with water like plaster.
Of course, I only found out what I was doing wrong until after Halloween, and I couldn't find the liquid stuff I needed. Luckily, in the meantime I have not only found a store that has it, but also a better recipe for foam coatings! The problem with the Monster Mud was that it was quite brittle. Perhaps this was because I used the wrong kind of joint filler, but my props were easily damaged. Another mixture that's supposed to be a bit more flexible and durable is Van's Super Scenic Dope, also known as VSSD or simply Scenic Dope. It has acrylic caulk mixed into it to make it more flexible, and much less joint compound.
The recipe calls for a quart of paint, four tubes of caulk and two cups of joint compound. So, in metric units, that's (approximately) one liter of paint, four tubes of caulk and half a liter of joint compound. For the paint, I mixed some leftovers white and black paint to get a gray base color.



 To give it some additional stone texture, I also mixed in some fine white sand. I didn't really measure the amount, I just eyeballed it until the consistency and texture seemed right. Keep in mind that the amounts of ingredients can be varied a bit to make the coating harder, more flexible, etcetera. Oh, and I used the cheapest paint and caulk I could find. No need to use the fancy, expensive stuff here.

Base coating
Before I started applying the foam coating, the engraved text was painted. This was done with plain dark gray paint, because the scenic dope would fill up the letters and ruin the details.
After the text had dried, I started putting on the scenic dope. I invited some friends to help me paint; after all, we had twelve stones to paint (thanks again, guys, you all rock!). Of course, some of the dope ended up in the letters anyway, and we had to use a small brush to clean them out again.




The mixture was very thick; if you'd paint with it like you'd do with normal paint, you'd end up with very visible brush strokes. To avoid this and get a nice, even stone texture, I used a dabbing motion with my brush. Another advantage of thick paint is that it also serves as a joint filler to fill up seams!




I had to do two coats of paint on each side to get good coverage. It took a while for all of it to dry, but the effect turned out great! Mixing sand with the paint gives it an excellent rough stone texture.


One word of advice, though: don't use expensive brushes with this mixture! Use the cheapest one you can find, because you'll probably have to throw them away afterwards anyway.

Shading
After the basecoat had dried, all stones had an even, gray color. To break this up a bit, I took some gray, purple and black paint, mixed them to get a blueish gray and applied them with a sponge and lots of water. The rough texture of the surface quickly wore down the sponge, wich actually made it easier to work with! In the meantime, I also painted the text and all the cracks a dark gray.




The final shading step was applying a white drybrushing. This technique is especially useful for rough surfaces, like the one I have here. The grains of sand pick up the white paint nicely, and you end up with a very convincing stone texture.






 


 


Finishing
I had planned to do some more finishing touches, such as adding fake moss. I wanted to use sawdust and green paint for that, but unfortunately, time was against me. Since I didn't know how weatherproof the scenic dope was, I clearcoated all the stones with a matte varnish, wich almost gave me a heart attack...
You see, I had used a ballpoint pen for marking the foam. It had bled through the first layer of paint a bit, but the second layer had covered it up nicely. However, the varnish had somehow dissolved the ink and made it bleed through all the layers of paint! On most stones it wasn't very visible, because I had used the pen mostly to mark cutting lines, but for example the Jack Sparrow stone had a few very visible lines on it.
What was my reaction when I saw this? Well, if you have ever seen that Mr. Bean movie, where he ruins a painting, that's more or less how I reacted! Luckily, they weren't ruined, a little bit of gray paint, followed by a final layer of white drybrushing fixed it.

vrijdag 29 september 2017

New Tombstones, part 1

When I started this blog in 2013, one of the first things I made was a set of tombstones. Now we're four years later, and the tombstones have been retired (read: smashes to pieces and thrown in a dumpster). In the meantime, my skills have also improved a bit, so it's time to build new ones!


I apologize in advance for the crappy photos. The lighting in my garage is horrible, and taking pictures of bright foam sheets is quite challenging! 

Materials and tools
When I built my first stones, I used expanded polystyrene foam (EPS). The problem with this material is that it's very soft and fragile, it's the kind of foam that has all those nasty little white beads. Now I'm using extruded polystyrene foam (XPS), wich is harder and doesn't have those little beads. It's a lot easier to work with, especially for engraving text. With EPS, it's almost impossible. On my first stones, I used a wood burning tool, wich gets waaaay too hot; with XPS foam, you can use a Dremel.
For glueing them together, I used a polyurethane based wood glue. This costs a bit more than regular white wood glue, but it's much stronger. PU glue slightly foams as it cures and fills any gaps. I tested it first on some scrap foam, to make sure it didn't dissolve it. Polystyrene is easily dissolved in many solvents, but apparently this glue didn't contain any of them.
So, without any further delay, here's the complete list of materials. It doesn't include painting supplies yet, that's for the next part!
  • 2 cm thick XPS foam plates
  • 16 mm diameter PVC pipes
  • PU wood glue
  • Band saw with 24 tpi blade
  • Hot wire cutter
  • Wood burning tool 
  • Respirator
  • Dremel with flexible shaft
  • Grinding stones and diamond engraving bits
  • 80 grit sandpaper 
  • Wood leftovers (plywood, melamine, ...)
Designs
I wanted my large stones to be the same size: 80 by 50 centimeters. The reason for this is that I'm also building a tomb that will serve as a storage box, and they have to fit inside. The remaining space will be filled with smaller stones.
I took out my sketchbook and started designing the large stones. At first, I printed some reference pictures of real tombstones, but eventually I ended up designing most of them from scratch myself. I didn't add too much details, most of them would be added on the fly anyway. I did keep the proportions and scale in mind, so it would be easier to transfer the designs to the foam plates.


 One major flaw in my first stones was that I forgot something to keep them standing upright. I ended up using duct tape! This time, I'll glue a few pieces of PVC pipe to the back, so I can use sticks to keep them in place.

Basic shapes
With the designs ready, I got started on the basic shapes. Each stone consists of two panels of foam glued together, with the details carved into them. I first cut out the inside shape of the front panel, glued it to the back panel, and then cut out the entire outside shape of the stone. I don't know if this explanation makes much sense, I hope the pictures do a better job.


Next up, I cut some decorative profiles in some of the edges. I bought a new hot wire cutter, this one uses a much thicker wire that can be bent into shape. Mainly the inner edges got a profile cut into them. The outer edges were rounded by sanding with 80 grit sandpaper.


Besides 80x50 cm tombstones, I also made some 30x50 cm tombstones. I had already designed the tomb I wanted to use for storing and transporting the stones, and I had some space left. In total, I will make seven large stones and five small ones. The small tombstones will have names of children from horror movies (Georgie, Samara, Jumby, ...).



Carving details
The most important details were the names on the stones. I typed them on my computer, printed them and then needed to find a way to transfer them to the foam. Problem is, carbon paper doesn't work, it simply doesn't show on foam. However, simply taping the paper in place and tracing the letters with a pen worked fine. The outline was slightly carved into the foam and easily traced with a ball point pen.


For carving, I used a Dremel. If you want to do fine detail work, a flexible shaft is a must have. I hung the tool itself from a hook on the ceiling, so I could easily move the handle on the flex shaft around.


I started with a grinding stone to remove a lot of material fast from the letters, and then used a thin diamond engraving bit for carving out the exact shape of the letters. Medium speed is best for engraving foam; too fast and the foam will melt, and there will be globs of molten plastic in the letters.



I also carved some decorations out of foam scraps. For example, Jack Sparrow's tombstone got a Jolly Roger skull, and John Kramer's a puzzle piece.


Wear and tear
Of course, the tombstones should look old, damaged and worn. With styrofoam, the perfect way to do this is with a wood burning tool. I melted out large chunks of foam, and carved cracks in the foam.



A very important warning here, styrofoam releases very nasty fumes when melted or burned. This should only be done outside or in a well ventilated area, and you should definitely wear a respirator!

Keeping them in place
Like I said, my first tombstones weren't really stable. I did add some sort of base, but nonetheless the slightest breeze knocked them over, and I had to improvise with duct tape. This time, I took my precautions!
First of all, I cut 6 cm long pieces of 16 mm PVC pipe. I then carved a channel in a chunk of foam, put the pipe in it and glued it to the back of the stones, so I can use sticks to keep them up.


Second, I cut some strips of leftover wood and attached them to the bottom of the stones with glue and screws. This protects the base of the stones a bit, and makes them bottom heavy and thus more stable.


Showcase!
Here are a few of my finished, unpainted stones. I tried to carve Beetlejuice's face in the stone, but he looks more like Doc Brown...

A few of the little ones:


The next step in painting, but that's for the next post!