Saturday, June 6, 2009

Removing the Rib Structure from the Mold

The time has come to remove the rib structure from the mold.  The first step is using a small hammer to free the four corner blocks from the mold (note that these pictures are just for demonstration, so in actual practice it is best to use your other hand the stabilize the outside of the rib or block on which you are hammering -- here, I used my other hand to take these pictures):


Then, the hammer is used to lightly tap along the linings to address any excess glue that may have accidentally dripped in between the ribs and the mold when the linings were glued:


With the four corner blocks and ribs freed from the mold, the corner blocks are split.  It is best to start by splitting a small piece of each block to test how the grain runs so that there are no surprises on the other side of the block.  If the grain doesn’t run parallel, the block should be split from the side where the angled split removes more wood:


Once the four corner blocks are split, the upper corner blocks should be pushed outward so that they are free of the recesses in the mold, as illustrated in the somewhat blurry picture below – this is really the key to easily removing the ribs from the mold:


The next step is to use the hammer to free the upper and lower blocks from the mold:


Then, after a final check that everything (all ribs and blocks) are free from the mold, the rib cage is carefully “peeled” off of the mold:


Here is the separated rib structure and mold.  Note that the blocks, linings, etc. will be trimmed and cleaned up in a future step:



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