I finally got caught up with other client’s orders, crates and more so I did a little bit of work on this today at least, rough laying out the design as this begins.
The Mulcaster building was once located at 1156-1162 (incorrectly designated as 1297 according to one source) Third Avenue, NYC (demolished ca 1965) on it’s facade was this spandrel panel, probably more than one:
Dates: ca. 1885
Dimensions: 25″ x 28″ x 7 1/2″
Located in the Brooklyn Museum, Gift of Mr. and Mrs. Benjamin Frost.
Description: Pressed, fired red terracotta rectangular plaque with head of youth, a butterfly-boy or girl sipping nectar from blossoms through a straw.
I decided to make my version of this 19″ high, 22″ wide which is the same proportion but a little smaller and this begins with the box form for the shape:
I made the first cast this morning from the new mold, the mold was not terribly difficult to work with but it’s very large and since the plaster shell of it is fresh it still has about 5 to 6 gallons of free water in it that has to evaporate out, meanwhile the extra weight of the water adds about 50 pounds of excess dead-weight.
I still need to cast a master to store away for future use in replacing the mold, and one for a client’s order today as well.
It took 4 gallons of water in two 5 gallon buckets mixed with the cast-stone to make enough slurry to fill the mold.
Those full 5 gallon buckets are heavy as hell to lift with the wire handle they come with, it’s about 68# each when full and I filled 2 up for the cast of the other gargoyle Nr 170 that I did yesterday not remembering exactly how much it would take. I had mixed up 2 full buckets as my notes from the last time I cast one of those indicated it took 4 gallons of water and I couldn’t remember if that was to completely fill the mold up with some left over, exactly the amount needed, or if was short, so I used 4-1/2 gallons of water to be on the safe side and those buckets wound up taking 50# and then some of the cast-stone. I wound up with almost half a bucket full left over, fortunately I was able to use part of it elsewhere on the spur of the moment.
The first cast in the Old Limestone Grey finish.
The mold was removed from the clay model last night, it was difficult to pull the rubber off since it was pretty thick/stiff in places it needed to be and a lot of undercuts and keyhole areas, the original unfired clay model mostly surviced the mold making process, only the curled tail broke off but it was a fairly clean break and it can be repaired so that eventually- I hope- when I buy a larger kiln I can try firing it.
Nr 170 did not survive the mold making process but that’s ok, I have a plaster master from it and the mold.
The models were all made from Georgie’s “Three finger jack” clay which is a cone 8-10 high fire clay, this model if I ever get to firing it will have to be slowly pre-heated around 200 degrees F for quite a while, and then very slowly fired probably over a couple of days time and then slowly cooled down under a powered-on slow schedule rather than having the kiln shut completely off at final temperature.
Now I will be working on building the supporting shell for the mold today.
I just finished all of the required sections and at the moment I’m waiting for the last/bottom section to harden fully before taking the mold apart.
I decided to do the plaster shell in the modelling studio instead of the basement because with the rubber and the board the model is around 120# and that’s a bit much to try and manhandle through three doorways and then down a narrow flight of stairs.
The first picture was taken around noon, the last one around 7 PM so it’s easy to see how making ashell like this takes about a day.
I started the mold for this this morning, so the progress on that is happening, the rubber portion should be finished late tonight.
Now the rubber portion of the mold is completed, having used up 3 gallons of the compound. I ordered 4 gallons knowing that like the first one it would take more than the single 2 gallon kit, they run $200 each so this one model used up $300 worth but I have enough left over now to replace 1 or possibly 2 small corbel molds that needed replacements for a long time.
The next step is building the complex plaster support shell for this, I figure about $100 worth of materials there to complete the mold plus my time, so it’s easy to see how this size model takes around $400 in materials alone just to make the molds for, it’s easy to see why I no longer just make molds automatically of new models untill there’s a firm purchase for the cast. In this case the model was finished in 2007, had I made the mold back then it would have sat around unused for the last 6-1/2 years before even selling the first cast.
The rubber portion has an unknown shelf-life purportedly being many years, but even without being used at all the rubber eventually will chemically break down, weaken and have to be replaced at some point.
At this time I am working on setting up this model for the mold as a client has purchased a cast.
This model was made along with four others in Dec 2007 but at the time only one had been molded, the other three awaiting specific paid orders to make the molds for due to the costs involved.
The photo shows the model being set up, the red/brown material is a non-hardening wax/oil based clay and this design needs four so called dividing shims so the rubber mold will be able to open around these undercuts. The tail curl has a hole through it, so in order to remove the mold from that a dividing wall has to be placed inside that hole so the mold can open like a coat around it. Same goes for the ears and the head/neck.
Hard to believe this has been sitting stored away for 6-1/2 years, and that it also has not been damaged since it is very soft still raw unfired, but dry clay. He weighs around 90 pounds and I have had him on a dolly in the studio, out in the front parlor, back in the studio, off the dolly under the table, and then finally down in the basement where with great difficulty I wrestled it down the stairs (keeping in mind the fragility) and now I had to wrestle him back UP the stairs to do the mold. Once the rubber part is completed he has to go back downstairs- AGAIN! to build the plaster shell since that work is so messy.
A client tentatively wishes to purchase a couple of at present designs that do not have molds available for them, one is one of the four Public School gargoyles and the other is the sitting winged lion after those on 90 West Street- both models completed a few years ago but never molded due to lack of any serious interest in them.
These two should be available very shortly.
Just for sharing/education I thought I would describe how I usually find the scales of things from photos, which I do a lot for my sculptures.
Here’s one wall of the map room in the NY Public Library, I already know it’s 34 feet wide because I found that fact in an article, so I would first look around for something of known size, if an adult person is standing there you can use a rounded out 6 feet for the scale, in this case the only known size is the width of the room.
Now I want to find out the size of the corbels in that cornice or entablature at the top of the wall, but notice the round top pseudo window in the center means that cornice is broken and there are none across that space to count, so I made a red box across 6 adjacent corbels, briefly moved it over to the pseudo window and could tell that space would have had 6 corbels across it.
I counted 9 corbels on each side, plus the 6 comes to 24 total spanning 34 feet, 34 ft x 12 inches = 408 inches, divided by 24 corbels means each is spaced 17-1/2 inches center to center, now we’re cooking because we have a measurement to use for all the rest:
Now I imported a cropped, lightened up and slightly desaturated to reduce the shin of the gold- enlarged version of the picture into CAD software, and after scaling the picture properly using that 17-1/2″ measurement I was able to begin making measurements of landmarks to start with:
The good thing is the original picture was taken pretty straight-on, and with a minimum of paralax angles caused by taking a photo looking up at something tall, there is a little here because of the height of the ceiling, but one can get reasonably close enough measurements with this that using a little fudging will get it accurate enough for this use.
If I lacked the room width to begin with, that EXIT sign and that wall clock would be the second choice for scaling off in CAD, because those exit signs are a pretty standard size and can be determined with a search, the wall clock too but it’s a little less likely to be any standard size, but most of them around this size would be around 16″ across- it would be my last choice to scale from if I have other choices.
We see the wood cornice with the corbels is 3 feet 3″ high, the coffers in the photo due to the angle of view give us the illusion they have height we can measure just like the cornice- they do have heigh, but if we were to measure that coffer from this photo going from the top of the dark cornice up it would be wrong due to the angle- the measurement that way is actually from the projection of the cornice’s edge towards you at the camera which is measuring the room length not the coffer’s depth- thats the optical illusion one has to be careful of when scaling off photos!
I was able to extract 4 more measurements above the coffers and if one looks carefully there is another optical illusion between the two 6-1/2″ measurements because that section of the ceiling projects horizontally towards the camera just like the coffers are.
The top measurement of 1 foot 11 inches is another major molding, a concave repeating molding with beed and fluting designs, it sits on top of a 6-1/” tall egg & dart molding, the other 6-1/2″ molding is a Greek styled leaf design.
We also can see the green painted wall is 7 feet 1 inch from the wainscot to the cornice bottom, the pseudo window is 8 feet wide, and the shield over it is 2 foot 9-1/2″ wide.
So in just a few minutes we have the majority of the measurements needed, the rest can be found with other photos, and whatever is missing can be guessed at with reasonable accuracy.
This photo would provide the square coffer’s width, we can assume that one IS square and determine it’s other measurement front to back, the one to the left of it would be the same front to back, it’s width can also be found in this photo and it’s rounded corner approximated easily although very hard to see here- there is a quarter round DOME above the pseudo window and that shield is not directly over that pseudo window as it appears- another optical illusion- it’s actually several feet closer to the camera, this also tends to make the measurement of that ( 2 foot 9-1/2″ ) a little incorrect because it is closer to the camera/viewer than the wall where the cornice is, but the camera is far enough away the error is really minimal here.
I also discovered when I lightened up another photo of that cornice- between each corbel there is a lion’s head carving, and each one is holding the end of a swag which curves along the bottom of each corbel which can be seen in the above photo.
So that is the method I came up with years ago.
I was reading a number of articles on this gothic styled 60 story building which is now 100 Years old, the whole of the facade is made up of over 16 MILLION pounds of terracotta made by the Atlantic TC Co.
The building’s facade has more than 400,000 units of terra cotta. Due to the lack of maintenance, the anchors attaching the terra cotta to the steel frame rusted and caused widespread damage to the terracotta panels. Many broken pieces have had to be replaced with new terracotta, or in some cases, an alternative material which these days is usually cheap fiberglass replicas or fiberglass reinforced concrete.
By 1978, just 65 years old- the building’s four smaller towers were badly disintegrated due to constant exposure to the elements and faced structural issues. The cost of terra cotta replacements was described as “shocking” at the time. Budget constraints led the architects to instead stabilize the towers and cover them with pressed aluminum sheaths that loosely resembled the original silhouette and color scheme.
That has me thinking again about this scenario which I’m seeing a lot of- extensive (translate that into costly) restorations and replacements of damaged or destroyed elements, all of this costly work had to be done on this building that is only now 100 years old, logic and common sense tells us that if the building needed all this work in the first 100 years, it will need it again within the next 100 years! But if the architects and all thought the replacement terracotta costs was “shocking” now, imagine what the cost will be 100 years from now!
So THEN what happens? just keep replacing, and replacing and replacing? at some point there will be so much replaced with cheap fiberglass and other materials there won’t be a lot of the original left, and by 100 years from now the elements put in today will themselves be 100 years old and deteriorated to the point they have to be replaced too, with the original elements now 200 years old.
If the building was damaged by years of poor maintenance who can say we won’t see a repeat of that?
Unfortunately only two people on my mailing list responded to the last newsletter asking for input on interest in any of the 10 or so photos of possible designs for the next model.
I’m leaning a lot towards this Assyrian themed Art Deco on the 1928 Ageloff Tower building, I remember seeing this in person years ago.
It measures over 9-1/2 feet wide on the building, if I did one half of it as shown by the red box and reduced it’s scale a little a 19-7/8″ x 30-3/4″ model would retain the same proportions and be a more practical size.
It would be a pretty easy model to make really.
I decided to stain the floor, door and wainscot to see how they look using Cabot Walnut stain, the mahogany floor looks very good in person, a bit red in the photos, but the color in person looks nice, as well as aged, the basswood doesn’t stain really evenly but gee, in the future there’s no reason I couldn’t make the wainscot out of mahogany, ditto for the stairs, the only issue would be the moldings, I’m not thrilled by the design of the Northern scale lumber’s baseboard profile I could come up with a much better one if I research what machine it could be cut on and have a custom cutter or router bit made for it (thinking of the possibility of selling them as well)
I would think the baseboard, door case frames and crown molding would not be difficult, the tiny moldings such as the 1/8″ quarter round probably won’t look any different when stained whether they are basswood or mahogany.
I need some more stair tread wood now I ran out, think I’ll make what I need since it’s just flat strips anyway.
A couple of photos from today, one with the chair and table set in place to see how they look, I pencil marked the primed wall, down and around to give me some idea where the wainscot or similar will go, above that line will be wallpaper, under the stairs behind the table will be filled in with panelling. The window in the “dead space” can be seen through the doorway, it will need interior trim, it is primed and the visible part of that room will have a different treatment on the wall, likely wallpaper to the baseboard.
I find that I’m not as happy with the Houseworks door as I was but it’ll do for this, I sanded down the too thick threshhold to about half it’s thickness and rounded the two edges. The door itself is only hinged with a couple of pins from the top and bottom, it’s hinge side was rounded out in an unrealistic way- done to allow the door to open without hitting the frame, I’d rather have real hinges and hardware, and squared edge.
Also the face boards of the HouseWorks door frame are somewhat crude- two vertical grooves, but given the bulk of the market these are geared for – dollhouses, they are very nice little works of craftsmanship, but for something aimed towards higher quality they are on the crude side.
These certainly could be given a much nicer, realistic profile with an appropriate cutter or router bit.