Freeform Square Nine Feet Long?!

Yes! One of my big projects in 2024 was to create an oversized freeform square shapes wall sculpture, coming it at nine feet! It is a beast, but it is still beautiful. Here’s a photo gallery showing the fabrication, from start to finish.

The parts are stacked in the van, just back from the water jet cutter. I need to dry them off and unload them.
The parts have been cleaned, sorted, and separated. Now they are ready for grinding and edging.
Meanwhile, Mike handles the equipment to get set up for assembly.
Old school technology is used to project the final design on the wall to actual size.
In the middle of surfacing. It takes multiple passes with the grinder to get a perfect finish.
We custom-built this grinder to help with the edges of the pieces. We still sometimes need small files and other hand tools to get into tight corners.
Some tracing and stenciling will give us a full-size drawing which we can use to align the metal pieces for assembly.
Mike has managed to project the design onto a large sheet of paper taped to the wall.
This is a precision operation.
Creating the stencil first, then the design will get adapted into a jig to hold the metal parts for welding.
With so many parts, we needed to be organized and label everything.
With such a large piece of artwork in production, it monopolized the entire studio for a few days.
A quick break for shadow puppets.
Markings and labels covered our template.
A finished section, welded and sealed!
But it was worth it. We finally had pieces laid out on a jig and ready to weld.

Freeform Square Nine Feet Long?!

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