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Steps in fake rock wall construction - illustrated (sort of)

zoniguana Mar 16, 2004 10:16 AM

Hi all

There have been lots and lots and lots of threads about fake rocks, lately, so, I thought I would toss this up real quick...

We started off with a hare-brained idea of mine, of using insulating foam sheets as the basis for a building material. It's lightweight, and rigid, but, can be semi-difficult to attach branches to... And, of course, water could be a big issue... So, fiberglass... Worked pretty well, except for the minor detail that the foam crushes pretty easily when attaching the branches, and we ended up encasing the whole thing in a thin shell of wood. All in all, it worked out pretty well, though the fiberglassing was butt-ugly...

So, we decided to paint the fiberglass and pretty it up a bit. 2 cans of Krylon camo paint (I liked the idea of ultra-flat finish) and we had a dull khaki/drab green motteld background that worked pretty well, though everything looked pretty grey in there, especially with the driftwood and the *grey* rat snake inside... Time to play...

Decided to try the fake rock approach, just monkeying around with the spray foam to give some shapes and textures... We dumped most of a can of Great Stuff in there and got corners nicely sealed, as well as some blobs on the walls. Just before the stuff dried, I stood the terrarium up and the foam sagged, creating an almost cave-like water-sculpted drippy look... Wasn't intentional, but, we liked it...

Step whichever, get dirty with tile grout. We skipped the gloves and went straight for the get grubby with the hands (the stuff washes off easily) and had a blast... Tile grout got slapped all over the interior, completely coating everything but the screen at the top and the brances, which were still glued into place. We also used the grout to smooth over areas where snake poop could collect & make cleaning a nightmare. That was allowed to set for a week. before we worried about any futher steps.

Once the grout cured, fully, we started with the painting (after masking off the branches, door tracks, screen, and outer wood shell). We decided on a contrasting color of primer to act as an undercoat for the rock. The rust-red primer made by rustoleum worked nicely for us. Once that dried (for the most part, it was dry in about 40 minutes) we added the first can of Fleck-Stone green granite. That dried for a goodish while. We left it for the afternoon, while we went and got a second can, having discovered that the first can was nowhere near adequate for what we wanted to do; it was dry when we got back, so, we sprayed the second can.

That sat overnight before we slapped on the tile grout sealer. The stuff we got is a silicon emulsion in water. It makes everything look really pale until it dries... This is OK... Let it look pale; when it dries, it's nice and clear. It's low-odor, and we're now waiting out this week for curing before we stick slinky-girl back in there...

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Justin, Julie and the menagerie...
www.baskingwonders.com

Replies (11)

zoniguana Mar 16, 2004 01:02 PM

np

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Justin, Julie and the menagerie...
www.baskingwonders.com

zoniguana Mar 16, 2004 01:03 PM

np

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Justin, Julie and the menagerie...
www.baskingwonders.com

oogieboogie Mar 18, 2004 03:45 PM

That shows how to build the fake rocks...

The link is in my signature.
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heartmountain Mar 17, 2004 07:56 PM

Looks nice... A lot of people seem to be using this 2 part foam (it's what's in the can) stuff here lately and I was wondering if anybody has mentioned that one of the things this stuff off gases is cyanide. We were using a lot of this stuff while putting in a new wing of the museum I work for and the gasses were picked up by the HVAC system making half of an entire dept sick before anybody realized what was happening. Just something to consider, I think it looks great though.

Sean
Heart Mountain Herps

trevorbennett Mar 18, 2004 02:05 AM

i didn't know that!!! well, it's good that i'm doing it in a well ventilated area. how much do you think it would take to do that?

trevor
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Trevor Bennett
E-mail: yruemailinme15@yahoo.com
yahoo SN: yruemailinme15
location: Salem, Oregon

heartmountain Mar 18, 2004 06:25 PM

I really don't know how much it would take. We were doing a 2 story wall with it (cliff face) in a well ventilated museum, it was actually the ventilation system that carried it to the people affected. It was the dept that was physically closest to the construction that was most affected, and then really only the people that were sensitive to asthma and allergens. I wouldn't mess with the stuff in my basement or my lizard room just to be safe. I think that after it is done curing that it would be alright though. A good test would be to seal it up warm it up with some heat lights for a while and then open the door. If you smell anything it's probably not done. At the meeting we had where this was brought up, they mentioned a safer material polyethalene foam, but I don't know how commercially available it is.

Sean
Heart Mountain Herps

zoniguana Mar 18, 2004 05:26 AM

I don't recall anybody mentioning it, but, as with any other chemical, allowing time for that off-gassing to finish and the "stuff" to cure is extremely important. Paints, epoxies, varnishes, stains and the like all give off harmful fumes (in the more friendly cases, those fumes are in small quantities, but, they're still there).
This is also why it is so important to work in a well-ventilated area. Even after we think the chemicals (be they paint, sealer, or anything else) have cured, we bottle up the terrarium (drastically reduce its airflow) and let it sit for a day. When we open it, we usually catch a good whiff of the fumes, which tells us it isn't done, yet.
We did our foam spooging 3 weeks ago. Then, the next week, we grouted. A week later, we sealed. Turns out the sealant wasn't the greatest. After several days' curing, when sprayed with water, the walls got decidedly slimy. We decided to topcoat with a couple coats of polyurethane varnish, which has left a nice sheen to the rocks, and stayed dry and easy to clean. We're hoping to move Blinda back in there today or tomorrow (today's the bottle & sniff test)
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Justin, Julie and the menagerie...
www.baskingwonders.com

zoniguana Mar 18, 2004 05:27 AM

PS-
Thanks for the "looks good" comments!
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Justin, Julie and the menagerie...
www.baskingwonders.com

zoniguana Mar 18, 2004 10:05 AM

So, here is the terrarium with acrylic doors in place, satin varnish dried and cured:
varnish on sealer on fleckstone on primer on spray foam on paint on fiberglass on foam insulating board, encased in a wood shell which has also been varnished...

I like the effect the varnish had, of making the "rock" look slightly damp...

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Justin, Julie and the menagerie...
www.baskingwonders.com

zoniguana Mar 18, 2004 10:07 AM

aw heck... not quite the final result... we still have to stick in the fake plants to make it purty for slinky girl...
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Justin, Julie and the menagerie...
www.baskingwonders.com

zoniguana Mar 18, 2004 10:09 AM

PS-

The "bullseye" in the middle of the door is because of the ability for acrylic panels to flex so easily that a semi-determined rat snake was able to force the doors apart and escape...

So, we soldered a nut to a big washer, drilled through the doors and pushed a thumbscrew through... Not terribly distracting and it works (until we decide to build a much nicer terrarium, once we get moved...)
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Justin, Julie and the menagerie...
www.baskingwonders.com

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