Here are some photos of the construction process for this structure… I started with a form made of foam core board:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1030.jpg)
1/2" thick foam core plugs were used to create the openings for the door and windows:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1037.jpg)
Rock was broken up into small bits with a hammer, then I used tile nippers to shape some of the stones as I placed them into the form. (Later I found a pair of curved tweezers which made it much easier to reach into the tight spaces):
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1043.jpg)
The most square stones were used in the corners:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1045.jpg)
Brass “rebar” and hardware cloth were placed over the stones:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1054.jpg)
Then the mortar was added. I used a mix of high strength mortar and vinyl patcher:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1059.jpg)
The form was tipped over and stones were laid into the next section of wall, followed by hardware cloth:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1065.jpg)
This process continued, working my way around the structure one wall at a time:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1080.jpg)
The mortar didn’t get worked down into the stones properly in a couple of places on the corners. As a result, some of the corner stones fell out when the building was pulled from the form:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1098.jpg)
I fixed this by gluing stones into the gaps. Dry mortar mix was sprinkled onto the wet glue between the stones. This made the glue look like mortar:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1104.jpg)
On one corner, the mortar oozed under the stones:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1101.jpg)
I carved “stone” shapes into the exposed mortar and then painted them to match the real stone:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1106.jpg)
The second level of the structure is made of styrene, scribed and painted to look like wood. Here’s a close up view of the front wall:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1166.jpg)
I broke off a piece of hacksaw blade and fit it into a hobby knife handle. This was used to scribe “wood grain” into the styrene. A hobby knife was used to carve cracks and other details:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1119.jpg)
I’m finally having a little success at building my own window frames:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1169.jpg)
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1170.jpg)
Here’s a small vent for the attic:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1171.jpg)
And here’s where I’m at so far:
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1174.jpg)
(http://www.raydunakin.com/IRRWebfiles/StoneHouse1/wIMG_1178.jpg)
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