OK, just for Steve, I worked under threat of severe thunderstorms. So far everything is dry For the last few days I’ve been working on the last piece of the portal, the face. Originally I wanted to model one of the EBT tunnels, but my terrain is too different, so I decided before I poured the wing walls that I would model the EBT’s utilitarian concrete design, but not an exact replica of any tunnel. A second consideration came into play a week or so ago when I realized that this piece was going to close in the opening making access from the portal end more difficult. I made the decision to try and make this pour a cast-to-fit removable piece. The form work was some of the most complex work on this project to date. Since a fairly large portion will be supported by a relatively thin pice, I decided it would need a serious rebar cage. This is what I came up with for the form and the cage… [url=lsc.cvsry.com/Post/DeepCutTunnel-48-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-48-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] I used some luan plywood attached to the inside of the form with headless pins to create some EBT style detail… [url=lsc.cvsry.com/Post/DeepCutTunnel-49-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-49-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] [url=lsc.cvsry.com/Post/DeepCutTunnel-50-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-50-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] Here is how the rebar cage is supposed to fit in the form. In practice, I added some concrete first, then pushed the cage into it… [url=lsc.cvsry.com/Post/DeepCutTunnel-51-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-51-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] To keep the concrete from bonding to the existing portal foundation and wing walls, I covered them with plastic and duct tape… [url=lsc.cvsry.com/Post/DeepCutTunnel-52-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-52-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] The form in place, ready for concrete… [url=lsc.cvsry.com/Post/DeepCutTunnel-53-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-53-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] I poured using a mixture of concrete and mortar to make it more workable… [url=lsc.cvsry.com/Post/DeepCutTunnel-54-1200.JPG]
(http://lsc.cvsry.com/Post/DeepCutTunnel-54-800.JPG)
[/url][color=blue]FF: Click to Enlarge - IE: Right Click Photo and select Open Link in New Window to Enlarge[/color] I’m going to leave the forms in place for several days, and not try lifting the finished piece for at least 5 days. I don’t want to take any chance of cracking it while still green. This is perhaps the most time and material consuming 7 foot of railroad ever built :o I just hope I have it finished in time for Fred’s funeral. The way he’s going that will probably be another 20 years or so. I think I have a slight chance of finishing in time