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Big Chunks of Foam - Our mold started with large blocks of foam which we cut out of large (8' X 4' X 1') sheets of this green foam. |
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Cutting the Foam - This year we attempted to cut out foam blocks with a hotwire. It was a quick effective way to cut, but the process did cause some burning of the foam and an annoying fumes. |
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Slightly smaller Chunks of Foam - After cutting down the large blocks we chopped down those large chunks of foam into smaller blocks which roughly represented the finshed shape of the canoe. |
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Finally - After many hours of hand carving we carved the canoe into just the right size and shape. |
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The Mesh - To strengthen the concrete, we put this steel mesh inside of it. We cut this steel mesh to shape of the canoe and lay it slightly above the mold with tiny little pieces of the mesh. |
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The Seam - Because of the shape of the hull, there is a seam in the mesh down the center of the hull. Here we are stitching it closed. We move onward to The Pour! |