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Tom Banwell offers one answer. His company in Penn Valley,
California offers custom resin casting in both urethane and polyester,
using silicone rubber molds. Tom also offers classes on making resin
castings and molds. He is an acknowledged expert in making resins look
like wood - see the resin reproduction of a woodcarving (below right),
showing the "grain" of the wood. A page on his Web
site (http://www.lumicast.com/wood.html) begins with...
| Resin can be made to resemble
wood, duplicating every chisel mark in a carving. End grain, cracks,
and the open grain of oak all come out looking just like the real
thing. Natural pieces of wood with or without bark and driftwood
are also easily reproduced. Wood stains, antiquing and paints
can be used to enhance the look. |

Copyright ©1987 Tom Banwell |
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Making plastics look like wood has been a constant
theme in the moldings world for a very long time. Witness the
excellent ceiling medallion from Century (shown above), with
a faux chestnut finish which blends beautifully with the wood
ceiling above it. Or the detail from Tom Banwell's "Sunface"
at left.
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Mixed Media
Applying a wood finish to moldings - to make them match the
natural elements in a project - is certainly a viable option
for woodworkers. But it isn't the only one. Urethane moldings,
especially architectural pieces, can be used extensively in
the woodshop - as accents on furniture and cabinetry, in frames
and fireplace surrounds and hundreds of other applications.
The finish doesn't have to be purist. It can be stained, painted
or dyed to a myriad tones and still work well with natural grains.
Using precast corbels or other elements is a very economical
way to add fine architectural detail to a project. Take, for
example, a couple of corbels like the one shown at left. If
they were ebonized (painted almost black), or even painted to
match the trim color in a room, and then used to support a thick
maple shelf, the opposing textures could be quite dramatic.
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It's even more fun to think about using one of the newest twists
in urethane moldings - Formaflex (TM). This is a series of flexible
moldings from Century
(shown at right) which follow a curve or arch.
Aside from the design possibilities presented by precast, extruded
or flexible moldings, there are a few other reasons to consider
using urethane products. For one, the cost can be quite a bit
less. Uniformity is another factor - these moldings are engineered,
not grown, so the intervals between the teeth in a dentil molding
will all be absolutely uniform. And defects are virtually eliminated
- annoyances like splitting, cracking, splinters, warping and
even rotting. Plus, you don't have to sand them, which on its
own is enough to make this old woodworker take a second look.
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Choices
One of the biggest upsides to urethane and similar
moldings is the huge variety of profiles available. While much
of each manufacturer's catalog is devoted to tried and true classical
moldings based on Greek and Roman architecture, some of the best
companies have extended their repetoire to include elements of
American and modern European architectural cultures. Colonial
and Federal artisans took classical forms to a new level and produced
in cast plaster what might not have worked so well in the original
carved marble. |
| Contemporary manufacturers are now nurturing
that evolution with wonderful moldings like the bent crown from
Style Solutions,
shown at left, above. Such innovative engineering presents woodworkers
with a whole new palette of materials and options. If, after a
visit to the sites mentioned here, you decide to take the plunge
and add this resource to your own work, please
let us know. |
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