“When nothing seems to help, I go look at a stonecutter hammering away at his rock, perhaps a hundred times without as much as a crack showing in it. Yet at the hundred and first blow it will split in two, and I know it was not that blow that did it, but all that had gone before.”
Last month I was commissioned by Chris Lauten, Northwestern Basketball’s Director of Operations, to fabricate a trophy for their off season competition called “Pound the Rock”. The honor is given to the player who embodies the values and principles of Northwestern Basketball on and off the court. Chris was thinking of something similar to the Nickelodeon Guts trophy but purple.
Here are some pictures taken throughout the process.
I started out by fabricating a foam-board pattern to cast a mold from.
I only had a few weeks to complete this and have it shipped before it was presented to the winner so I hired my pal Rick Payson to help cast the silicone mold and build the base for the trophy. This was the plywood box that covered the pattern and acts as the frame for the silicone mold.
This picture shows the pattern still in the mold. Once it was removed I post cured it at 145F for 8 hours.
Once the that cured, the foam layer is removed leaving 1/4″ gap. The gap will be filled with urethane resin to make the part.
I used Hapco’s Hapflex urethane with 1% violet tint added to the catalyst and I vacuum degassed both components separately.
With the actual piece to use as a guide, Rick and I built the base to follow the angles of the rock.
When the base was built, bondo’d and sanded, I primed and painted it in a flat black finish to offset the glossiness of the rock.