PRODUCTION DAY 12 - STORAGE & ORGANIZATION

Before embarking on final installation, we brought up and sorted each component in the PIT to ensure flexibility and ease of assembly. 

THE WONDERFUL UNDERSIDE

One of the more random occurrences in this project was the ability for us to identify intriguing moments that were not anticipated at the onset of design.

Here are a series of images revealing the underside of the glued surface

The underside under a lit condition

PRODUCTION DAY 10 - SURFACE GLUING THREE

On our final day of gluing, we were able to get through panels four to six. Our final piece was of course the name plate showcasing the team and its supporters. 

PRODUCTION DAY 9 - SURFACE GLUING TWO

Continuing with our precious process, we have moved on to panels two and three on the second day of gluing. 

PRODUCTION DAY 8 - SURFACE GLUING ONE

On the first day of surface gluing, we started off by laying out all the pre-assembled components into their respective slots in the Lexan backer panels. Through careful placement, we started the initial steps of the surface undulation and proceeded in mastering the steps of the gluing process.

All components inserted into the first two panels.

Gluing consists of one person allotted for dipersing the Corian glue, one for placement and the remainder of the team for holding each face in place. 

By gluing on a horizontal plane, gravity became our ally.

THE FINAL PRODUCTION SET UP

Today we set up our installation area. After completing all of the post-processing for each Corian component, we can now move on to all gluing processes.  

PRODUCTION DAY 4: GLUING FLANGES

Gluing jigs were prepared to ensure a 3" (the thickness of the backer panel)
offset from the base of the extrusions.  

Pre-cut flanges with holes for securing the components to the backer panels. 

The team in an assembly line fashion. 

 

Cleaning the jig.

Scraping excess glue.

 

The component drying in the jig.

The team hard at work.

The collection of completed components. 

  

A demonstration of the fitting.  

PRODUCTION DAY 3: SANDING PARTY!

An important process in the assembly of Corian requires extreme cleanliness when gluing. The team therefore went through a full day of sanding.

PRODUCTION DAY 2: GLUING EXTRUSIONS

Today, the team worked on gluing and finishing the extrusions that will soon be inserted into the backer panels. The fabrication and assembly process is as follows:

Pre-taped extrusions ready to be glued

Cleaning the extrusions with Methyl Hydrate

Brant gluing the edge conditions

Folding the panels to create an extrusion

Taping the extrusion closed

Cleaning the fully glued extrusion

The assembly line in action

 

Extrusions being hauled off to storage

A collection of finalized extrusions