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This 1.5'x3'x6' box is an exploration of materials and the solid/void relationship. As you take on this project, you are part of the maker community. I hope this encourages you to come up with your own project!

Basswood and rockite morph together to form a box, an exploration with many outcomes.

After you've accomplished this Instructable, you can fabricate other iterations with other materials as well.

Step 1: Materials

You will need:

For a 1.5'x3'x6' box

-Several basswood dowels and studs found at your local art supplies store

-Tacky Glue

-Foam core

-Rockite mix

-Plastic bag

-Tape

For the basswood, you should get a variety of lengths and diameters, preferrably two-three of each length/diameter. You will also need access to a band saw, or some other electrical saw, unless you're up to the challenge of manually sawing your project!

Step 2: Glue Your Basswood

Let's get started!

Remember that you're aiming for about a 1.5'x3'x3' box for the wood portion of this project, so the basswood dowels and studs will need to be about four to five inches in length to make the sawing easier for you. After you cute those, glue their lengths together [quick-dry tacky glue works best, or some other quick-dry glue] until you have a packed bunch that roughly measures 2.25'x4.25'x4' or 2.25'x4.25'x5'. I will be referring to the packed bunch of dowels/studs as 'the pack' from now on.

Wait for it to dry. Hopefully not too long!

Step 3: It's Sawing Time

Next, step up to the band saw. This is the tricky part, and may require you to make other smaller packs of dowels/studs to practice this step [highly recommended]. Make sure to wear shop/safety glasses or any other protective head gear!


You have a little bit of freedom here, but the best way of starting is by cutting small pieces at a time. Keep in mind the expected dimensions. Slant the pack diagonally and slowly run it through the band saw, keeping in mind where the cut will end. Next, lay the pack flat so the area that was just sawed is facing directly downward. Make a second cut right at the edge of the first cut to establish the first corner

Now look and examine your pack to see where you will do the next three cuts [one side of the pack will remain uncut]. Keep using the flat sides to help glide the pack on the band saw.

Step 4: Make the Formwork

Let's move on to the second half of this box.

It's time to fabricate the formwork for the rockite. Foam core is a good material and can also be found at your local arts supplies store. Cut five rectangular pieces so that the volume inside this foam core box is 1.5'x3'x2'. Lay it flat and make sure the open side is on top. One of the pieces will also have a hole in it to connect to the pack.

Cut a wide strip of the plastic bag, or any other similar material, and tape it tight onto the form core [the perpendicular side with the hole], and also wrap it around the end of the protruding dowels/studs. Tape this end tightly as well so none of the rockite seeps through.

Step 5: Pour!

After you've made sure the formwork is taped tightly, mix water into the rockite mix.

4.5 oz of water for every pound of rockite mix

Make sure the length from the end of the pack to the end of the formwork is 6 inches. Pour the mix into the formwork and wait for it to cure for about 15-25 minutes.

Carefully remove the formwork. The connection will be fragile.

Remove some of the excess material from the foam core and it's ready!

Congratulations!

<p>Clever use of materials. This method could be used to make some very interesting sculptures.</p>

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