Why not make your Halloween designs last forever?! You guessed it these are all concrete!…
This concrete takes on a new form as it becomes a bit french; Faux Bois which means fake wood. It lets me take concrete design to an even more tactile interesting level. This detailed project spans a few stages… But let’s get started; Part 1 of making this Concrete Faux Bois UpCycled Chair!
I have always marvelled at some of the amazing Faux Bois furniture that has been built by artists. It does however usually involve a welded heavy frame; something that I don’t do (maybe someday!) yet. However I did save a couple iron chair frames that are sturdy and have lovely lines. I knew someday they would hit their full potential.
As you see, they did not have any seat or back since they used to have rattan there. I have seen many a chair with this fate but now they will be a perfect starting point.
There are many ways to add some structure on the frame to hold the concrete. I chose to use whatever material I had on hand; wire (thick & thin tie-wire) metal mesh, plastic gutter mesh, hardware cloth etc and some filler like pool noodles and styrofoam. Only some basic hand tools like pliers, wire cutter, xacto knife, gloves are needed.
I made myself a raised platform (few mild cartons) to be able to work easily as a table would be too tall and the ground too low.
Oh, and did I mention pool noodles too? I had some images of branches in my mind so the round shape would work well. They are hollow in the middle and cut easily to allow placing over the wires. You can even use some pipe-insulation. The rules are pretty lax here.
It’s a Wrap!
Wrapping the mesh and filler around the frame was done with the tie wire. Here’s a tip; to give it a sturdy start make a hook that can be anchored into the mesh or styrofoam.
The Branch & Wood Designs:
Go look at some trees, really look. Branches are usually reaching upward and get thinner as they go. Alternatively they branch out etc. Trees are usually not symmetrical or perfect. I planned a thick branch to travel up and across and added new branches across the seat by first tautly stretching and twisting strong wire. Envision that there will be thicker branches there eventually. Any styrofoam can be used as it will allow it to be lighter and not absorb any moisture in the future.
The leg is like a tree base and curving along. Luckily I have much inspiration available all around me but you can even use the look of old driftwood.
Make sure everything is secured tight and no wires poking out. The plastic gutter mesh was very easy to work with but chicken wire is very similar.
There, do you see the new branches travelling across the seat?! The pool noodles are wrapped tightly with wire as well.
Can you imagine it? DOn’t be too fussy as there will be ways to liken it to branches even more later.
I had some ‘sneaky’ tricks that will help transform the arms later on so I left them for now.
Utilizing Fabric with Cement:
You may know my Step Spook, he has held up great so I am utilizing this draped concrete method as a base coat. To start it is key to find the right fabric as my draped concrete tests as taught me. I prefer something with some way to absorb the portland cement but not be too fluffy and bumpy. An old polyester blanket was just right, thin but takes the portland nicely.
As with the Step Spook I used a Portland Cement slurry. It’s about the consistency of thick cream. If the portland is lumpy it helps to put it through a sieve.
If the fabric is very absorbent it may ‘steal’ the moisture from the concrete but I found that this could be added dry and massaged into the Portland mix.
Let’s get messy!
My intention with this Faux Bois is to wrap the branches well with the cement dipped fabric. Using thicker or thinner strips spirally wrap the branches smoothing as you go along.
This will be the first layer so you can be less fussy. I like the smoothness of the portland cement as I find the sand tends to not get absorbed.
It’s already taking shape… you just need a vision! As long as you can see it, is all that matters! Any parts than seem a bit thin can be coated with some of the Portland Cement slurry painted on so that once cured it’s a good strong shell.
I bet some of my neighbours were wondering what I was doing out back each day. It’s messy sometimes, so I keep these jobs for summer projects outside. Keep the mess down with some of my tips. You should wear a big apron and my new tip; double nitrile gloves!
It’s been brutally hot here so I covered the chair lightly to allow the portland not to dry too quickly as it cures. I even mist it regularly to strengthen it.
It’s not done, but the hard work is done! The next steps will take it over the top! I promise! Won’t you join in my journey of making beautiful permanent furniture out of something that could have ended up in the landfill! Let’s all make a Concrete Faux Bois UpCycled Chair…