People who visit us are most often surprised that our shop is not massive, nor is our crew large. There are only five full-time members on our team, and the main shop measures only 30’ x 40‘ with two small additions for the CNC router and plasma table, plus the studio. Although we each have our favourite tasks in which we excel, every member of the team happily helps out with all the jobs to make the work flow through the shop quickly. A medium-sized piece would typically be in the shop only 2-4 weeks at most. The key to producing the work we do is being somewhat organized and flexible. Although it can seem chaotic at times, there is a purposeful workflow and plan. We fabricate all of our features and signs on wheeled frames to allow them to be juggled around the shop as needed. Generally, the pieces in fabrication in the shop are in a variety of phases. We first weld the structure, then the pencil rod armatures, followed by the attachment of the diamond lath. A typical piece would take 5-7 work days to be at this stage. Sculpting is best done in just the right-sized batches so that we can mix, trowel on the fibreglass-reinforced concrete, fully sculpt it, and clean up by quitting time. The features are then allowed to cure for 3-5 days before we begin the painting and glazing, which takes another 5-7 days. This shot captures a typical busy, productive day in the shop.
First letters sculpted
It was the first sculpting day in some time in our shop, and the crew was eagerly looking forward to creating some awesome woodgrains. Four of the large DOWNEYS letters were ready, and the concrete was trowelled on and allowed to set just the right amount of time until it was carvable. Matt, a master of this craft, led the crew, and by the end of the day, all four letters were done. Tomorrow, the next three will be done. Each letter will soon be painted a rainbow of colours, and we checked our stock to make sure everything is ready and on hand for next week, when this process will begin. Stay tuned…
Tire horse structure
There was lots of progress on the letterswhen I was away! Matt finished welding the pencil rod letter armature fronts in place, and the crew has already tied the lath on four of the letters in readiness for sculpting beginning tomorrow morning. While the crew worked on the letters and prepared the mixing area, I began work on the structural steel for Kraay’s Horse Carousel entrance. Although it may not yet look much like a giant tire horse to most people, I can clearly see it. Stay tuned to watch it come together…
