Each buoy has 5 “dishes” on the spire, and one “cone” as a transition between the orange float and the spire.  Each mold needs an inner and outer surface pattern.  I make a rotational extrusion in clay or plaster for each shape.

The molds are silicone with plaster backing.

Float test of one BAD BUOY in G & W’s pool, Maple Leaf Neighborhood.

Fabrication is complete and assembly/installation is next.  See below for blow by blow of fab work.

Casting starts with a paint coat of resin with blue or orange dye on the lower mold surface.  Reflectors are placed by hand.  Kind of like dealing cards.  Casting run is 30 pieces.

Molds ready for casting with dyed surface suspended to create a void.  Resin is poured from the edge.  Then demold and heat treat overnight at 160°F in the kiln. Low temp, but it really adds strength to the castings.

Spires are acrylic tubes with sparkles and color inside.  Ya gotta spin em.

24” diam TuffBuoy barrier float .  2” x 15”  steel ballast was waterjet cut by DaVinci’s Workshop Inc & galvanized by Scott Galvanizing Co.  Bad Buoys are lookin’ good during float test in G & W’s pool.  February 19, 2009.

Maple Leaf Reservoir under construction in background, completion 2013.

Stow for 90 degree tip over!

Float Test  21 second video

BAD BUOYS vignette

Fabrication Images

SURGE

Thornton Creek Water Quality Channel

© Benson Shaw 2010

A project of the Seattle Public Utility

and the Office of Arts and Cultural Affairs

Page updated:

26 May, 2013

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