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I have started a building front for a customer (an apartment building). I have in the past used two methods to create window spaces. Most of the time I cut a solid wall (styrene) and use a nibbler to cut out the window spaces. However sometimes when I have a small wall and a lot of windows that need to line up precisely I use the 'cookie cutter' method as shown below. The wall is made up of individual pieces of styrene. Window spacing is set using hardboard spacers.

The brick sheet is laminated to the styrene with a spray contact cement. All windows and the door will need to be custom built. 

I cut the door arch by first tracing a line with some tubing that was the right diameter, then I used a Forstner bit and a hammer to cut a groove deep enough to allow me to finish the cut with an exacto blade. A round sanding disc finished and smoothed the arch.

The brick sheet was extended down the entire length. I will cover it with 'concrete' sheets later on.

Joe

 

Brenneman Building [3)

Brenneman Building [1)

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Did some more work on the building front.

The front door entrance has an arched entry. I traced the archec on a piece of 40 mil styrene then used a compass with needle point to start a groove. I finished up with an exacto blade.

Brenneman Building 05-20 [1)

Brenneman Building 05-20 [2)

The rest of the entry way was straight pieces of 40 x 250 styrene. I then used 30 x 60 mil rectangular strips. Glue the top portion first then work your way down.  

Brenneman Building 05-20 [3)

Brenneman Building 05-20 [5)

I then started on the window trim

Brenneman Building 05-20 [6)

 

I hope to have more status this Sunday.

Joe

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I have been working on the windows. I first glued the exterior aprons to the brick face then I glued the casing to the insides of the windows. After the casings were installed I started working on the interior sashes and muntins. I am leaving the upper exterior trim till last since these will be the most difficult to build.

I was toying with the idea of building the sashes and muntins as a complete box and gluing to the inside of the window but decided against it since it would complicate gluing the window 'panes' in.

Brenneman Building 05-20 [6)

Brenneman Building 05-21 [1)Brenneman Building 05-21 [2)

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Rex / mark:

Thanks

Did more work on the windows. I decided after all to glue the muntins internally. I glued support rails on both sides of the window and the muntin in between so it will be easier to glue in the 'window panes'. Since this is a building flat what I did is ok. If this was a four sided building I would have built the assembly as a box. I found it a lot easier to do this rather than cut all the muntins to size.

The internal muntins are shown below.

Brenneman Building 05_25 [1)

Next came the upper exterior trim. I started out by scribing a ring on 40 mil styrene with a needle point compass.

Brenneman Building 05_25 [2)

 

Brenneman Building 05_25 [3)

I cut the trim to size then used the leftover inner circle to cut the half moon trim that sits rigth above the window casing.

Brenneman Building 05_25 [4)

I outlined the top trim with 20 mil styrene stock. The end result is shown below. I will most likely leave the trim off the brick until after painting. This way I can the brick  / mortar then tape and paint the windows. Taping will be much easier with the top trim off.

Brenneman Building 05_25 [6)

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Did some more work on the apartment building front.

The sides were laminated and attached to the front. I used a double layer of 80 mil styrene to add stiffness and glue surface. The styrene was laminated with a Plastruct brick sheet.

Brenneman Building 001

To make the door I used 40 mil styrene, cut out the window holes with an exacto blade. The panels are more 40 mil styrene cut to size. The trim was 40x60.

Brenneman Building 002

With the bottom concrete trim done I started the cornice. First course was some 40 mil sheetwork. To make the roof brackets I used Grandt Line  Victorian brackets (see below). An insert was used to make sure the spacing was exact. I started by gluing brackets at each end then one in the center. I then measured the space in between one end bracket and the middle bracket to make the wood spacer.

Brenneman Building 003

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The top courses consisted of two 80 mil and one 40 mil sheet cut at a 45 degree angle.

Brenneman Building 005Brenneman Building 006

Next up are the stairs and railing then this building should be ready for paint.

Joe

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The steps and stairs are done.

The top level of the steps started out as a box. The bottom portion are 1/4 in square rods stacked on top of each other (1, 2, then 3). Making the steps this way gives a 45 degree angle which is useful (see below).

The railing has to be scratched built. I use 60 x 60 and 40 x 60 strips. Since the angle is 45 degrees construction was relatively easy.

Next up is paint.

Brenneman building 001Brenneman building 002Brenneman building 003 

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Started to paint the structure - 

All plastic brick will get a dark gray primer. The brick will then be oversprayed with a 'Heritage' red color. the customer likes the darker red brick (see the top of the sample panel next to the building). The popouts, cornice and steps will get a coat of light gray then off white to give a dirty painted cement look.

I will have to take the painting slow. There will be a lot of taping needed so I need to let the paint cure for a few days before applying any tape. My plan is to tape the windows, cornice and bottom first and spray the brick color. Once that is cured I will tape the brick and paint the concrete.  Once everything dries I will add the mortar.

Brenneman building 06-24-2016

Joe

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Last edited by Joe Fauty

Joe

Like those who posted, I really appreciate the step by step.  But what also impresses me is your architectural details:  The corbels along the roof line are echoed under the window sills, the arch trim above the windows match the curve of the upper window frames, the keystone above the door arch, the panel molding on the entrance door, and the 45 degree grates over the windows at ground level. Little things like that greatly contribute to the both the realism and the interest of the building.

 

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