Installation

The existing wood facimile of the cornice is removed after the second casting from the mould is ready to install.

(Suitable before and after photo - excluding the paint stage - I will show below in leaping ahead. )



Preparations to hang the cornice are made as illustrated by the cross-sectional drawing.

The separately cast Bead & Ogee moulding (section A above) is fitted and installed with screws into the wood framework and acts as a level ledger after making a reference line between the other two pilasters with a string line.

Expanded metal lath is screwed into the existing plaster, prepped by some Dara-Weld to insure proper integration of the old and new, then overlayed with Structo-lite plaster and let set a full day.

The side pieces to the pillaster were then brought up from the casting area and fitted to size, after grinding on the sides with a diamond impregnated disc.

It is at this point where extra plaster can be installed along the back and important allignment compromise is arrived at. Though the mould is taken from the other side of the room for depth difference considerations it is found to have inconsistencies in lenths of "skirting" below the Egg & Dart from merely the front to the side, which both castings are taken from. The existing cornice across the southernmost section of the west wall seemingly grows in size vertically as well as "takes a half-inch dive" into the pilaster's southern corner, presumable to accomdate the pilaster that was once there. Now I'll have to adroitly do the reverse freehand with plaster! What a challenge!

It is hard to imagine in hindsight whether or not this discrepancy could have been solved out through modification during the casting process. My mind has ruminated over whether an extra joint at the corner would have made it more adjustable in fitting up. but the complexity and patching factor would have doubtless gone up by half or more. I spent one whole day sealing up the mitres and seeing if my efforts to freehand a transition made some difference. Here are the results: