How to Assemble Dimensional Wall Sculpture Designs
(see Dimensional Wall Sculpture Designs for examples)Do the layout face-up on mylar taped to peg board– carefully draw lines around each piece while it is flat on the mylar. Use a red sharpie with a good point, then do the corners (inside and out) with a fine-tipped black sharpie
Note – the mylar should really be stapled in place, as well as taped
Label each piece and, at each intersection, identify what level riser will be required
Flip the mylar – retape and restaple
Cut all the risers from 3/4" dowels and blacken twice. I use black paint mixed with varathane for the 1st coat
Make sure the cut off saw is zeroed in both dimensions. Check the heights of the risers against stacked pieces.
Do a test fit with all the piece upside down
Draw on the back of each piece where the intersection will be, both above and below. This will greatly help with line-up later. I have rulers that are the same widths as the pieces
Doweling the longer risers to the undersides: One tip is to file the splinters off the dowel rod before gluing it in place – this will greatly help with fitting
Assemble the whole design upside down. Make sure everything is lined up with the mylar map - use the orange squares to check the higher pieces. Especially make sure the +3 and +5 risers are centered properly.
Clamp the level 1 and level 2 pieces
Make sure the pieces are lined up perfectly, and spaced properly
The orange clamps are necessary to prevent the pieces from moving while drilling
Drilling the holes: Mark the drill spot with a magic marker, then with an awl
Drill the first hole with the Dremel and a 1/16” bit – do all – go through both layers
Then pin all holes with extra 1/16” bits or Tig rod
Drill the next hole – 1/8” – go through both layers
Use the countersink tool on the top piece
Prepare the risers – drill ¼” holes through the centers
Line up the 1- and 2-level pieces, with the risers in place
Pin the holes with extra 1/8” drill bits
Screw in the first screw 1-5/8” long – check to see if the tip needs to be cut off – use a slow speed and a torque setting of 9 - put a little dab of polyurethane glue on the end of the screw
I use black drywall screws - the thread is further apart and they really grab the pieces and pull them together
Check to make sure the riser has snugged up tight between the two levels
Be very watchful that the drill or the screw doesn't twist the pieces. Probably best to do the final screw tightening with a hand screwdriver.
Keep going until its all done.
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