Introduction: Small Climbing Wall
For this project, I will be taking you through the process of the construction of the climbing wall.
Foam, Exacto knife, Polymer clay, Silicon mixture, Choice of wood, Plastic resin, hot glue, Power tools: hand drill, dremel, sander Paint
Step 1: Cover the Foam Model
Constructing the holds.
In this step, I took foam core and cut it down to resemble a shape that can be used in multiple ways and angles. The shape that I went for has many different options for hand holds, foot holds, and finger holds.
Thinly roll out a piece of clay. I used polymer clay because it is safe to set in the silicon mold. Other types of clay may also work. I covered all of the cracks with more clay so that no silicon would seep into the cracks and create extra holes.
Step 2: Create Foam Box
With a lazor cutter or an exacto knife, cut a box out of foam core. I used a knife with layers of hot glue.
Step 3: Fill the Box
In this step, I put the model in the box. I had to use skewers to hold it down so that it would not float up when the mixture was poured over top. I then poured the silicon mixture on top and waited for it to set. This process took 30 minutes.
Step 4: Cut the Mold
After the mold set, I used an exacto knife to carefully cut the mold in half. For this step, I used an extra set of hands to pry the mold open as I cut it open.
Step 5: Pour the Resin
I used rubber bands to hold the cut open silicon mold. I then mixed the plastic resin mixture and poured it in the mold. After this, I waited 15 minutes for it to set.
Step 6: Alter the Hold
When the plastic hold comes out of the mold I sanded it and made alterations. This was the finished product of the first hold. It has many different hand placement options.
Step 7: Replicate Holds
I decided to cut the remaining two holds into separate pieces which could act as smaller holds. I then sanded them down.
Step 8: Attach the Holds
I drilled holes in each of the holds with different sized for the bigger and smaller ones. I then attached them to the wall.
Step 9: The Unfinished Project
I tried many different ideas such as creating a peg bored and an overhang. Neither of these worked, but I did add two more panels so extend the shape of the wall.
Step 10: Cut Bolts
To touch the wall up and make it hangable, I used a dremel to cut the back of the bolts off.
Step 11: Paint
I decided to paint the wall mainly white with hints of purple and red. After this, I let it dry and sanded it down slightly.
Step 12: Hang
We used six screws to drill the wall to another wall. It was then time to test it.