Carving a Bear of Out Epoxy and Wood

19,706

244

63

Introduction: Carving a Bear of Out Epoxy and Wood

About: My name is Blake, I make things for a living. I love experimenting with new materials to create sculptures, furniture and everything in between.

I poured 9 gallons of epoxy resin along with various species of wood and power carved it into a bear sculpture. I first milled walnut, mahogany, white oak, poplar, redwood and pine. I used various woodworking tools to get them all identical in thickness. I then used Mas epoxy 'Deep pour X' to pour all 9 gallons of resin over the course of 3 weeks. Once cured, I carved the massive block by using a chainsaw, angle grinder, die grinder and various sanding tools. There were a lot of challenges along the way but I am beyond pumped with how this sculpture turned out. Let me know what you guys think in the comments!

Step 1: Check Out the Full Build Video!

Materials used:

1. Epoxy- Get 10% off by using code "Blake" on Checkout! https://masepoxies.com/product/handy-...

2. 20V Chainsaw (highly recommend) - https://amzn.to/3hQpvD2

3. Wood Finish- https://amzn.to/3xmPTcc

4. resin dye- https://amzn.to/3yqOJOd

6. die grinder- https://amzn.to/3xqiOMB

7. Orbital Sander- https://amzn.to/3CbVOEB

8. Sawzall- https://amzn.to/3fuKkST

9. Face shield- https://amzn.to/3CbW9XT

Step 2: Mill Lumber

I first milled up Walnut, Mahogany, White Oak, Redwood, Poplar and Pine by running them through the jointer to get one perfectly flat side. I then ran them all through the tables to make them the same height and thickness.

Step 3: Cut, Glue and Plane

I varied the different species of wood to get a random color pattern. I then cut them all at different lengths. I glued up 10 boards together because that is the thickness of the bear. I had to glue up 20 different pieces in order to get the length of the bear. I then ran all 20 glued up pieces throughout he planer to make them perfectly flat.

Step 4: Mold and Epoxy Pour.

I created a melamine mold to fit the giant wooden piece. I used epoxy to laminate all 20 pieces of wood. I then used penetrating epoxy to seal all of the wood to prevent bubbles from forming. I poured 9 gallons of epoxy over the corse of 2 weeks. I did 6 separate pours so the epoxy wouldn't get too hot and fracture. I also did the pour inside with a temperature of 73 degrees and a constant overhead fan to keep the heat down. This was a long process but this would be unable to be poured in one shot so it was the only way to accomplish a perfect pour of 9 gallons.

Step 5: De-mold, Outline Sculpture.

After a week of fully curing, I de-molded the wood and epoxy. I was so happy with how crystal clear the epoxy turned out. I then outlined the bear on the side of the sculpture to use as reference for the carving.

Step 6: Chainsaw Off the Bulk Portions

I used my 12" chainsaw to remove large amounts of material. I made sure to stay away from my reference lines around 1" to prevent any fractures from happening too close for comfort.

Step 7: Further Refinement

I used the angle grinder, die grinder, reciprocating saw and sanders in order to refine the shape even more. This took around 5 full days to refine it to my liking.

Step 8: Sand, Sand and More Sand.

I sanded the entire sculpture down from 40 grit on the orbital sander to 1000 grit. This was a tedious task because I had to do the majority of it by hand.

Step 9: Finish

I used 4 coats of Odies Oil to treat the wood and epoxy.

Step 10: Check Out the Full Video!

Be sure to checkout the full video for a more detailed explanation as well as the finishing shots!

Be the First to Share

    Recommendations

    • Eggs Challenge

      Eggs Challenge
    • Backyard Contest

      Backyard Contest
    • Meatless Challenge

      Meatless Challenge

    63 Comments

    0
    WendyH62
    WendyH62

    Question 4 months ago on Step 10

    love this, I was wondering if the penetrating epoxy to seal all of the wood to prevent bubbles from forming, was brushed on and did you still have to monitor bubbles with a lighter for this process?

    0
    Yonatan24
    Yonatan24

    8 months ago

    I didn't realize how big it is. Nice, I love it.

    0
    SmileLove
    SmileLove

    10 months ago

    Wow! You put a lot of time and dedication to this... Glad all went well!

    0
    lisa.shorey
    lisa.shorey

    11 months ago on Step 10

    This is absolutely beautiful! Do you sell them somewhere? I would love one!

    0
    artOfacts
    artOfacts

    11 months ago on Step 10

    Just wow... I love the details of your sculpture and the way you described your process. I am a furniture redesigner—I find old pieces that I like and redesign them. i have a project for a table with a marble top that I have wanted to combines with an epoxy resin pour so I am looking for different ways other artists have used other materials along with resin. Thx for sharing your process!

    0
    kevin.m.miller2
    kevin.m.miller2

    11 months ago

    In the area where I live we have a lot of what the locals call "Butte rock". It is a soft cream colored stone which is found just about everywhere, approximately 6-10 inches under the surface of the ground. For a long time I have wondered how to preserve artifacts such as your bear, carved out of this substance. I want to try what you did after reviewing your process, but instead of laying up wood, use butte rock as the carved substance, then coating the object with the resin you used. If it can happen, my first attempt would be that of a Tatanka, the American Bison native to this area. Peace!

    0
    loopyelaine
    loopyelaine

    11 months ago

    Absolutely amazing. I may never be able to make anything like this but i have learned a lot from your video. You are so talented 😊

    0
    Design•Time
    Design•Time

    11 months ago

    Beautiful build! Thank you for sharing!

    0
    Sockmonkey22
    Sockmonkey22

    11 months ago

    WOW - so glad you shared this one

    0
    megagigatroninator
    megagigatroninator

    11 months ago

    This is incredible! Apart from being a great build, it just makes me happy to look at. Nice job man :)

    0
    BMsculptures
    BMsculptures

    Reply 11 months ago

    0
    Lina Maria
    Lina Maria

    11 months ago

    I love it!!!!❤️ It's an amazing project, you are very talented, congrats!! 😊

    0
    tdwain1
    tdwain1

    11 months ago

    Well done! I'm curious as to how much 9 gallons of epoxy cost you?? 😮😮👍👍

    0
    DorthyE
    DorthyE

    11 months ago on Introduction

    Simply beautiful. I am in awe and am going to follow you from now on.