Large Demensional Caps-Part 2

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OLD FORUM POSTS

Posted by Jon Harl on February 03, 2004



Hey guys Shane Durford e-mailed me with an explanation to my post about crown moulding. Pretty interesting. He also sent some pics of recent work. Just like all the work I've seen that he's done really top notch. I like it.

Thanks Jon, positive feedback is always welcomed.
The cap for the Collingwood Library is redwood and was somewhat of a complicated method of lamination and splines. Now I make my caps out of HDU (high density urethane), it is much faster and much less complicated and will not split or move like wood. I basically use two different methods for making caps of HDU.

1 - for small caps I cut the rough shape out of a sheet of 2" HDU, cut out copies that are close to the same shape to the desired thickness, cut out the final shape on the band saw, sand to smooth finish, run through a shaper or large router bit for profile, finish ends by hand with chisel and sandpaper, channel out .25" depth to fit over top of sign panel (makes for a cleaner job). On larger caps, like the attached picture of the Heritage Complex, is the same process but the peak was shaped by hand.

2 - for larger radius caps I make a jig that is slightly smaller radius than actual sign, clamp 1" thick x desired width pieces to thickness required, glue together with west systems epoxy and clamp to jig. Cut ends on band saw and shape by hand. Channel depth to fit over sign panel.

There are no books that I use or know of but it might help to go to a wood working or cabinetmaking shop to ask questions or buy books on these subjects. Best of luck.

Shane Durnford

PS - I will be offering seminars and when I do I'll let you know.

John Harl

Second photo. Mike Jackson helped me in posting the photos-Thanks Mike!