carving the arches
refer to the photos on the last entry
the first thing I do when carving the window/door arches is cut a blank of foam that is as wide as I desire for the outside diameter if the arch. I want each arch to be close to the same height, so I line up the bottom of the blank with the top horizontal mullion on the door/window casting. I center the window/door casting on the blank and trace the top curve of the casting on the foam . at this time I also make three reference marks at the top center, and where the two angled mullions are. this gives me a reference for the keystone placement, and the cut lines for the stones that make up the arch.
With the reference lines on the foam, I draw two more arches, one above, and one below the original arch line. the inside (lower) line, I taper outward a little on the bottom, to help it line up better with the stones on the sides of the opening. I also draw in the keystone. then I cut that shape out. at this point it is way too thick. where the angled lines that mark the stone cut lines are, I extend those lines down the sides of the block of foam, so when the top is shaved off that location mark won't be lost.
Then along the lines of the keystone, I cut halfway down into the material. then I come from the sides, starting at the bottom. and shave about half the material off the arch, up to the keystone cut line. this gets the sides of the arch to approximately the desired thickness. the keystone is a little fat too, so I shave a little off the front of it. then I use the reference lines on the sides of the arch to remove a little material to make the lines between the stones on the sides of the arch. then with a little clean up, and beveling of the edges, it is ready to glue on.
I used the yellow foam from a chicken tray for this set of arches, as I though it would photograph better than the white foam. It did, it was also a little denser than the white foam ( Midwest foam, purchased at Hobby Lobby) , and was actually a little easier to work with than the white stuff. I wish I'd learned that earlier, as there are only two more window arches to carve, on the end wall opposite the tower.
Bill Nelson
refer to the photos on the last entry
the first thing I do when carving the window/door arches is cut a blank of foam that is as wide as I desire for the outside diameter if the arch. I want each arch to be close to the same height, so I line up the bottom of the blank with the top horizontal mullion on the door/window casting. I center the window/door casting on the blank and trace the top curve of the casting on the foam . at this time I also make three reference marks at the top center, and where the two angled mullions are. this gives me a reference for the keystone placement, and the cut lines for the stones that make up the arch.
With the reference lines on the foam, I draw two more arches, one above, and one below the original arch line. the inside (lower) line, I taper outward a little on the bottom, to help it line up better with the stones on the sides of the opening. I also draw in the keystone. then I cut that shape out. at this point it is way too thick. where the angled lines that mark the stone cut lines are, I extend those lines down the sides of the block of foam, so when the top is shaved off that location mark won't be lost.
Then along the lines of the keystone, I cut halfway down into the material. then I come from the sides, starting at the bottom. and shave about half the material off the arch, up to the keystone cut line. this gets the sides of the arch to approximately the desired thickness. the keystone is a little fat too, so I shave a little off the front of it. then I use the reference lines on the sides of the arch to remove a little material to make the lines between the stones on the sides of the arch. then with a little clean up, and beveling of the edges, it is ready to glue on.
I used the yellow foam from a chicken tray for this set of arches, as I though it would photograph better than the white foam. It did, it was also a little denser than the white foam ( Midwest foam, purchased at Hobby Lobby) , and was actually a little easier to work with than the white stuff. I wish I'd learned that earlier, as there are only two more window arches to carve, on the end wall opposite the tower.
Bill Nelson