Introduction: Carving a Swan From Epoxy and Buckeye Burl
I carved a swan out of a massive piece of Buckeye Burl and 13 gallons of epoxy. I first cut the buckeye to the appropriate size. I then spent 2 weeks doing 6 separate pours of epoxy to get the volume I needed for the carving. Once the epoxy was cured, I used a chainsaw as well as other power tools to carve the swan out of the block. I then spent an absurd amount of time hand sanding everything before applying finish. I am really happy with how this sculpture turned out and eager to hear what you guys think!
1. Epoxy- Get 10% off by using code "Blake" on Checkout! https://masepoxies.com
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. Arbortech Turbo Plane- https://amzn.to/3vYWzyj
9. Arbortech Contour Sander- https://amzn.to/3mwaoRO
10. Arbortech Powercarving package- https://amzn.to/316VpVU
11.Kutzall die grinder bit- https://amzn.to/2ZJMWHZ
12. Face shield- https://amzn.to/3CbW9XT
My Camera- https://amzn.to/2Lq0MED
Camera Mic- https://amzn.to/2LtpZ13
Step 1: Check Out the Full Video
Check out the in depth carving from start to finish.
Step 2: Buckeye Burl
I found an amazing piece of buckeye burl locally. The supplier cut the burl down to my specific needs. I then took it home and cut it down to a more appropriate size. I cleaned off all the bark by using a chisel, and then sandblasted the entire burl getting all the dirt/debris out from all the crevices.
Step 3: 13 Gallon Epoxy Pour
I first coated the entire burl with Mas penetrating epoxy. This will help prevent bubbles from coming out of the burl. I then made a melamine mold and placed the burl inside. I did 6 separate pours totaling 13 Gallons of MAS 'deep pour X' Epoxy. (get 10% off and free shipping by using code 'Blake' at checkout). You must do separate pours because if you pour over 2" you will get fracturing within the resin. I waited a full week before un-molding the epoxy.
Step 4: Trace Design and Cut
I then traced the Swan's outline on the epoxy and burl. I used a chainsaw to do most of the bulk cutting. I spent a couple days just forming the outline of the swan.
Step 5: More Detailing
Once the bulk was cut away, I primarily used an angle grinder with different attachments to further refine the shape. To get into tighter areas I switched over to a die grinder.
Step 6: Chop Off the Beak!
From the start, I knew I wanted to add a piece of buckeye for the beak. I very slowly and precisely cut out the epoxy beak, then used an off-cut of burl to create a new beak. I used epoxy to attach it back seamlessly.
Step 7: Sanding Sanding Sanding & Finish
I hand sanded every square inch of the swan from 60 grit up to 2000. This took a VERY long time. I then used an oil based finish to seal everything and give it that nice shine.