9/14/16

  Here we have the fiberglass mold reinforced with plywood ready for disassembly.

Here we have the fiberglass mold reinforced with plywood ready for disassembly.

  This shot represents the mold with the sides removed.  The next step is to clean up the edges and separate it from the pattern.

This shot represents the mold with the sides removed.  The next step is to clean up the edges and separate it from the pattern.

  While we were fabricating the mold we have also been preparing a computer program to water jet cut the butterflies from a sheet of stainless steel.

While we were fabricating the mold we have also been preparing a computer program to water jet cut the butterflies from a sheet of stainless steel.

  It’s an amazing process.  It combines water that is sprayed at 45,000 psi combined with garnet abrasive.  The dark in the center of the shapes is the garnet residue.

It’s an amazing process.  It combines water that is sprayed at 45,000 psi combined with garnet abrasive.  The dark in the center of the shapes is the garnet residue.

  This is the box of butterflies after being tumbled in a stone tumbler to surface the pieces and remove sharp edges.  660 butterflies in all!

This is the box of butterflies after being tumbled in a stone tumbler to surface the pieces and remove sharp edges.  660 butterflies in all!

  Here you can see the surface of the mold.  It is a negative version of the lips.  We have put a layer of foil on the surface to protect from the welding process.    

Here you can see the surface of the mold.  It is a negative version of the lips.  We have put a layer of foil on the surface to protect from the welding process.

 

  We are hand forming each individual butterfly to match the contour of the mold and welding it from the back.

We are hand forming each individual butterfly to match the contour of the mold and welding it from the back.

  This is a very labor intensive process as the stainless likes to move when heated so many adjustments must be made.

This is a very labor intensive process as the stainless likes to move when heated so many adjustments must be made.

  This area covered represents 3 guys working for 4 days.  Yeah it takes a long time…   This is what the surface looks like to date.  you can see the shape of the lips beginning to emerge.

This area covered represents 3 guys working for 4 days.  Yeah it takes a long time…

This is what the surface looks like to date.  you can see the shape of the lips beginning to emerge.

 The dark circles from the welds will be removed when the welding is complete.  We will cover the entire area of the lips and onto the surrounding skin surface before we are done.  

The dark circles from the welds will be removed when the welding is complete.  We will cover the entire area of the lips and onto the surrounding skin surface before we are done.