|Project by Gumnut||posted 07-08-2012 08:59 AM||2655 views||13 times favorited||26 comments|
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