ShapeCrete has an awesome projects website with tons of inspiring ideas. I liked this doorstop idea but though it would be more fitting to make one of the letters M-A-K-E for our makerspace. I decided to make one based on the ShapeCrete tutorial: http://www.shapecrete.com/projects/door-stop
Step 1: Prepare the Mold
1. Used some super thick roofing foam block insulation that had been found discarded behind our makerspace"
2. It was at least 4 inches thick
3. I forgot to take a picture but I basically drew out the block letters on the foam board with a Sharpie marker by hand.
4. ShapeCrete recommends using 2 inch foam block insulation and printing out the letters with a printer to make a stencil
5. After marking out the letters M-a-k-e and making sure that they all touched, I started to carve them out using a dry wall saw to cut through the thick foam. I didn't get pics of this either
6. After cutting, I put the mold face down on a piece of scrap oriented strand board (cheap plywood) and then used hot glue to secure it to the board and also to add the "holes" for the letters "a" & "e". Again no pics of this step
Step 2: Prepare the ShapeCrete Mix
- We neglected reading the instructions on the Shapecrete bucket and simply started adding water to some of the powder mix
- If the mix seemed to watery/runny, we simply added more powder
- We used an old discarded egg beater and stick to mix it all up
- The egg beater worked great
Step 3: Pour the ShapeCrete Mix Into the Mold and Then Let It Cure
- Didn't get any action shots but this is what it looked like after pouring the mix
- I used a flat stick to trowel it and make sure concrete was pushed into every nook and cranny of the mold
- After cleaning up, we let this sit in the mold for about a week due to other activities
Step 4: Remove the Mold and Sand It Down
- Pretty much destroyed the mold getting it off the casting
- Once again I used the drywall saw to cut the foam insulation mold off
- This step was too messy for photos
- After removing all of the insulation, I used sand paper to get the remaining bits of foam off and do general smoothing to the edges
- I started with coarse 60 grit sand paper and absolutely destroyed it in the process
- I followed up with 150 grit fine sand paper to finish it off
- I then used a broom to dust it off, followed by an air compressor to get it really clean
Step 5: Paint
- Last step was to apply some paint
- I used spray paint found in a bin at our space
- It had to be red
Thanks Instructables and Cheng Concrete for supporting these Maker Space Build Nites! I would have never done a project like this with their support.
If you are in the Atlanta area, come check out our makerspace in Marietta.