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A Box For A Competition (Opera House)

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Project by Gumnut posted 07-08-2012 08:59 AM 2524 views 12 times favorited 26 comments Add to Favorites Watch

As with my previous post (Pyramid Box), the same rules for the competition applied to this one as well.
Firstly, I made a mould from pine using an Arbortech Wood Carver to get the general shape, then I used a sanding disc on the angle grinder to smooth off the final shape of the mould.

I coated the mould with dental wax sheets, to prevent the finished Opera house sticking to the mould.
To get the wooden wedges to curve from top to bottom, I cut a kerf in the underside with a 0.2mm blade on a PROXXON saw. (Totalling 1,400 cuts) These were almost cut right through to the surface which allowed for easy bending! As it turned out the cuts made an impresion of tiles on the Opera House.

Each wedge piece was then pasted with two-part resin glue on the underside and wired into place on the mould in stages until full coverage was completed.

A thin jarrah strip was laminated onto the top ridge before sanding of the outside surface was carried out. I then placed the whole lot in the oven (without my wife knowing) to warm up the wax enough to then separate the Opera house from the wax-coated mould.

The inside of the shell was then cleaned and sanded to a point where I painted on an automotive acrylic primer filler, giving a smooth surface for the paint, being 3 coats of Midnight Blue Pearl Metallic automotive paint. 6 coats of acrylic gloss was then applied, with the aid of my wife’s hair dryer (again without her knowledge!) to heat up the paint and the shell surface for a very consistent gloss finish.

The outside of the shell was coated with 8 layers of acrylic gloss which was smoothed down with wet and dry between coats and finally polished with carnuba wax.

The base, the door, handle and the magnetic catch were made up of the left over 5mm planks and finished in satin estapol, then glued into place with the resin glue.
If you are going to try this, buy your wife a new hair dryer first!

It came first place in the competition!
I had intentions of giving it to Oprah (As Oprah’s Opera House), when she came to Australia but missed my opportunity!
It could be used for her remote control in her home theatre :)

The wood is Oak and Jarrah (Eucalyptus marginata).

Hope you enjoy the pics.

-- Peter, member of the Fine Woodwork Association http://www.fwwa.org.au/index.htm





26 comments so far

View michelletwo's profile

michelletwo

2284 posts in 1739 days


#1 posted 07-08-2012 10:45 AM

clever construction..ssweet

-- We call the destruction of replaceable human made items vandalism, while the destruction of irreplaceable natural resources is called development.

View Kookaburra's profile

Kookaburra

748 posts in 948 days


#2 posted 07-08-2012 11:07 AM

A very impressive box. And the story of the making is greatly appreciated. Congrats on the win!

-- Kay - Just a girl who loves wood.

View jaykaypur's profile

jaykaypur

3431 posts in 1131 days


#3 posted 07-08-2012 11:24 AM

W O W !

-- Use it up, Wear it out --------------- Make it do, Or do without!

View aviad mishaeli's profile

aviad mishaeli

93 posts in 1132 days


#4 posted 07-08-2012 11:28 AM

this is a beutifull shape and very intresting , i love it

View Arthouse's profile

Arthouse

230 posts in 1374 days


#5 posted 07-08-2012 12:01 PM

Innovative construction and design. I love it . You could be a model maker for Architects. Have you thought about using foam for you glue forms? A little easier to form. I just love the design of the opera house. If I may take the liberty and add to your thinking and say Instead of cutting to bend core because I think the cut lines detract from the total piece get wood and sand it thru a drum sander then slowly bend the pieces using a steamer until they bend into shape to hold for the wire. Still incredible piece hope you win your competition .

-- "The hand is the cutting edge of the mind but the wind and sun are the healing factors of the heart

View Spoontaneous's profile

Spoontaneous

1319 posts in 2053 days


#6 posted 07-08-2012 12:06 PM

Outstanding !!!

-- I just got done cutting three boards and all four of them were too short. (true story)

View Roger's profile

Roger

15055 posts in 1527 days


#7 posted 07-08-2012 12:14 PM

Wow! That’s amazing..

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View GrandpaLen's profile

GrandpaLen

1576 posts in 996 days


#8 posted 07-08-2012 01:06 PM

Peter,

Congratulations on your First Place Honor with this one (and 2nd place with your Pyramid box).

Your Opera House box is about 10 miles north of Incredible. – Grandpa Len.

-- Mother Nature should be proud of what you've done with her tree. - Len ...just north of a stone's throw from the oHIo, river that is, in So. Indiana.

View a1Jim's profile

a1Jim

112538 posts in 2300 days


#9 posted 07-08-2012 01:19 PM

Shee Zam that’s and amazing box and fantastic technique, you’ve got a winner there for sure. GREAT JOB!

-- http://artisticwoodstudio.com Custom furniture

View itsmic's profile

itsmic

1419 posts in 1842 days


#10 posted 07-08-2012 01:53 PM

Very Unique Box, Congratulations for the first place, Great job, thanks for sharing

-- It's Mic Keep working and sharing

View Gumnut's profile

Gumnut

95 posts in 881 days


#11 posted 07-08-2012 01:55 PM

But wait there’s more to come!
Will post some newer boxes soon!

-- Peter, member of the Fine Woodwork Association http://www.fwwa.org.au/index.htm

View WRAAdesign's profile

WRAAdesign

46 posts in 1122 days


#12 posted 07-08-2012 02:56 PM

Impressive, thanks for sharing your process; it reinforces the appreciation of the project and the time invested.

-- http://www.facebook.com/pages/WRAAdesign/142679579165522

View Greg..the Cajun Wood Artist's profile

Greg..the Cajun Wood Artist

5218 posts in 2032 days


#13 posted 07-08-2012 03:02 PM

Very excellent and unique. I can tell alot of work went into it.

-- Each step of every Wood Art project I design and build is considered my masterpiece… because I want the finished product to reflect the quality and creativeness of my work

View SPalm's profile

SPalm

4904 posts in 2605 days


#14 posted 07-08-2012 04:11 PM

That is just fantastic. I love it.
And thanks for the step by step. fun to see it develop.

Good job, and congrats.
Steve

-- -- I'm no rocket surgeon

View majuvla's profile

majuvla

3731 posts in 1591 days


#15 posted 07-08-2012 04:26 PM

Congratulations,wonderfull job

-- Ivan, Croatia, Wooddicted

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