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Question - 1 Filling in large gaps

16 years ago

I have almost finished the letters for "TurtleWalk". These letter are going to be like a doormat, but infrequent traffic, though they are made of wood. I am so excited about how it is turning out thus far and forget the helicopter, now I want a scroll saw for christmas!

No one knows what is going on with it except Marlene and DH, and Mrs. No, who actually gave me a thumbs up!!

Anyway, everyone knows you guys are the best shoppers as well as improvisors in the whole world and I need help please.

These letters are spaced normally Helvetica/Arial and there will be a significant gap between them. They are scroll sawed 1" PT deck pine and are about 8" tall.

I am thinking a couple of different things:

a) some kind of liquid resin that I can tint and carefully pour between them. It is going to get walked on - swept - snowed and rained and sleeted on - freeze thaw, etc. I don't want to bury the wood but pour only until it is flush with the wood.

What I am seeing online is like $100 a half gallon and I'll guess I am going to need about three gallons (I'll pre-measure with water) - at least, but also assume that it would be best to pour a single time - not layer? I don't really want to spend that kind of money at this point.

b) using either sand based tile grout or tinted ceramic tile grout?

Loaded question but, am I nuts?

Any suggestion?

Brian

Comments (12)

  • 16 years ago

    Wow, Big Deck. That sounds like a really cool project! I do know that wood will swell or shrink, according to the weather, so I'm afraid sand based grout would crack. I'm wondering if you could use wood filler in a contrasting shade as a sort of adhesive/grout? That's the first thing that came to mind. Good Luck! Kathy

  • 16 years ago

    If it was me and since they are PT I would just use some kind of gravel around them .I think that would be neet .I have also seen where some one put granet grav and sprinkeld it with cementand sprayed water and let it set up.
    Here is somthing I think you will like!!
    http://www.flickr.com/photos/24065392@N03/sets/72157605304292348/

  • 16 years ago

    DH suggested using fiberglass to fill in between them or to cover them for that matter.....hmmmm...guess you two should talk about that idea.

  • 16 years ago

    Any pictures? I am trying to figure out what it would look like. Would each letter be kind of like a stepping stone? Or would it be one long phrase?

  • 16 years ago

    I'd use concrete and smoosh the letters in...

  • 16 years ago

    Getting about 1 or 2 parts an evening done. Darn rain will not stop around here.

    Anyway, I keep thinking there must be some way to 'bond' the sand from Oscar's sandbox. Some of these gaps are no bigger than an 1/8" of an inch. Force the sand into the openings and then pour something liquid (maybe wood glue that is really watered down?) into the sand and hope it seeps?

    If Marlene gives me the go-ahead, I just might be willing to post a picture. All I can tell you is that as was the deck, this is a bigger project than I anticipated but one hell of a lot of fun!

    Calamity, I thought about concrete or plaster-of-paris, but I think the freeze-thaw cycles will turn either into dust in just a few months, and I don't know how I could clean them off the already sealed pieces.

  • 16 years ago

    Getting about 1 or 2 parts an evening done. Darn rain will not stop around here.

    Anyway, I keep thinking there must be some way to 'bond' the sand from Oscar's sandbox. Some of these gaps are no bigger than an 1/8" of an inch. Force the sand into the openings and then pour something liquid (maybe wood glue that is really watered down?) into the sand and hope it seeps?

    If Marlene gives me the go-ahead, I just might be willing to post a picture. All I can tell you is that as was the deck, this is a bigger project than I anticipated but one hell of a lot of fun!

    Calamity, I thought about concrete or plaster-of-paris, but I think the freeze-thaw cycles will turn either into dust in just a few months, and I don't know how I could clean them off the already sealed pieces.

    Oh, meant to include this is the last post - anyone ever work with decomposed granite?

  • 16 years ago

    What about using some type of thin-set and adding small stones pressed in to give a nice contrast to the wood? Then use a glossy sealer to make the stones pop??

    sandy

  • 16 years ago

    If you can get a picture (e-mail it to me if you like) I will take it to my scrollsaw group and get their opinions on what would hold up best. They are an awesome group! Scrollsawing is great fun. You can start out with a relative inexpensive scrollsaw and if you choose to stay with SS you can step to a better saw. My saw is relative inexpensive and works fine for me as I am not into SS as much as my other hobbies.

    ChelCass

  • 16 years ago

    chelcass - thank you for you offer, but you have selected respond without email address or something, as I can not respond to it.

    (PLEASE NOTE: The member responding to your post has chosen not to reveal his or her email address. Therefore, you cannot reply to this message via email.)

    :-(

  • 16 years ago

    Ok...POST A PICTURE!! They will be SO impressed with what you're doing!!! Then, maybe they can help you more with your questions. Some of our mosaic folks may have an answer.

  • 16 years ago

    Ok, I posted a new thingie!

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