Fusion Techniques

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Techniques

Fusion methods:

1.Alluminum Seams

2.Handsaw Seams

3.Nailboard Seams

4.Simple Stacking

5. Alaskan Seam

1. Aluminum

Tools:

Piece of aluminum larger than the surface intended to freeze

Iron

Ice Water

Procedure

1. When seaming ice it is recommended to have at least one chilled piece of ice (15 – 25 degrees).
2. Warm aluminum with Iron.
3. Prep the two surfaces that you intend to freeze. Make each surface as flat as possible with the necessary power tool. Once you have two flat surfaces you will then apply them to the aluminum. Now you have two completely prepped surfaces.
4. Align the ice to desired freezing position then immediately add Ice water around seam to fill in the gaps.

Techniques: Sandwich method

After prepping the surfaces apply the aluminum to the bottom piece and immediately place the top piece of ice onto the aluminum. Once in place immediately pull out the aluminum so the top piece slaps itself into place. You may have a couple of seconds to move ice pieces around in to position. Freezing is almost instantaneous.

Pointers:

• Look to the center of your seam, when the center turns a tint of gray then you know that your seam has bonded together.
• If you notice small gaps, take very wet and clean snow and throw into the seam.

If you leave the gaps unfilled water may enter the seam and refreeze to pop your seam loose.

• When seaming large aluminum surfaces (20” x 20”) and your ice is larger than the aluminum surface. If you have trouble creating 2 perfectly flat surfaces, pour water on bottom surface and then slap the top piece into position. This will displace the unwanted water and fill in gaps. Allow a few minutes for this seam to set. It may be necessary to slush the edges to hold the water in. This is only recommended for surfaces that are horizontal seams. If it is a vertical seam it could let go. Also if the temperatures are below freezing this process is not recommended.
• If it is snowing, do not allow any snow to enter the seam. This may cause the surface to have small imperfections and you may appear to have a good seam, but the seam may let go on you.
• If it is below freezing then the speed of attaching the two surfaces becomes vital. In this case the sandwich technique is highly recommended. If you take to long to apply the surfaces the water may refreeze on the ice and your surface can become wavy.
• When seaming a pre-carved piece to a carved piece of ice it may be beneficial to do a dry fit. A dry fit happens after you have completely prepped each surface. You will not attach and simply align the ice for proper placement. (Example: attaching an arm to the torso. You want to make sure the arm is attached in a natural position.)
• For sandwich method it helps to have two people.

Advantages

Can seem small pieces of ice together with ease.
Produces a nearly invisible seam.
Seam is strong (when not in sunlight) and instantaneous.
Method can be used easily for vertical seaming.

Disadvantages

If it is sunny, this seam allows the sunlight to penetrate and eventually weaken the seam, until it gives out.
This method requires electricity.
Aluminum should be larger than the size of intended seam.

2. Handsaw

Tools:

Japanese Handsaw

Ice Water

Procedure:

1. It is recommended to have at least one piece of ice chilled to 15 to 25 degrees F.
2. Prep the two surfaces that you intend to freeze. Make each surface as flat as possible with the necessary power tool.
3. Stack the ice to desired freezing position.
4. Run the handsaw through the two pieces of ice. The handsaw will bring the two pieces together. Snow will fill in gaps naturally as you saw. Continue sawing until both pieces meet, the seam should be free of gaps and stands on its own without wobbling.
5. Pour ice water onto top piece and watch to see as the water fills the seam. Continue pouring until water completely fills the seam.
6. If water continually runs out and does not fill properly take very wet and clean snow and throw into that part of the seam to block water from flowing out. Allow time for this seam to set, freezing is not instantaneous.

Pointers:

• To create a vertical handsaw seam, just freeze horizontal and allow time to freeze. Then stand seam to a vertical position.
• The handsaw process works best with heavier pieces of ice. The weight of the top piece of ice should hold its place through the sawing process. If the top piece cannot hold itself still you may be better trying another method (aluminum) or using a smaller saw.
• If it is below freezing you may continue to come back to the seam and re-water and re-slush the seam to fill in gaps. This will ensure a solid seam.

Advantages

If it is sunny, this seam will hold up. The snow left behind from the sawing process blocks out the sun and allows the bond to hold up under adverse weather.
This method can cover long horizontal surface freezes, great for building walls of ice.
Handsaw is lightweight and travels easily.
This method does not require electricity.

Disadvantages

Much harder to create a vertical seam.
This method is hard to do on small pieces of ice.
Seam is very visible.

3. Nailboard

Tools:

Nailboard

Ice Water

Procedure:

1. It is recommended to have at least one piece of ice chilled to 15 to 25 degrees F.
2. Prep the two surfaces that you intend to freeze. Make each surface as flat as possible by running the nailboard in a circular motion around the ice.
3. Stack the ice to desired freezing position.
4. Before adding water place a screwdriver as a spacer so that the water will run into the seam.
5. Pour ice water into seam and pull out screwdriver to allow ice to come together.
6. If water continually runs out and does not fill properly take very wet and clean snow and throw into that part of the seam to block water from flowing out. Allow time for this seam to set, freezing is not instantaneous.

Pointers:

• If surface is larger than a 20” x 20” you may use a v chisel to create grooves for the water to flow into the center of the seam. Be sure to slush these grooves closed when finished.
• If it is below freezing you may continue to come back to the seam and re-water and re-slush the seam to fill in gaps. This will ensure a solid seam.

Advantages

If it is sunny, this seam will hold up. The scratched surfaces left behind from the nailboard process blocks out the sun and allows the bond to hold up under adverse weather.
This method can cover long horizontal surface freezes, great for building walls of ice.
The nailboard process works best with heavier pieces of ice and over large surfaces.
This method does not require electricity.

Disadvantages

Much harder to create a vertical seam.
This method is hard to use on small pieces of ice.
Seam is very visible.

4. Simple Sacking

Tools:

Syringe or water bottle

Ice Water

Procedure:

1. It is recommended to have both pieces of ice chilled to 15 to 25 degrees F.
2. Stack the ice to desired freezing position.
3. Pour ice water into seam.

Pointers:

• Process is only recommended for setting up pre-carved ice sculptures on-site.
• Be sure that surfaces are completely prepped before leaving the shop.
• Be sure the seam appears in an optimal point of the sculpture design.

(example: a slab of ice with the logo engraved can be placed on a simple base like a column)

• Do not use warm water, and do not pour an excessive amount of water on sculpture. Only pour enouph water to fill the seam. Small water bottle or syringe works great in this situation.

Advantages

This method is good for saving time on deliveries.
This method does not require tools, a cup of water can be retrieved on-site.
This method does not require electricity.

Disadvantages

Does not create a strong seam.
Only works for horizontal seaming of a well-balanced ice sculpture.

5. ALASKAN SEAMING METHOD

Tools:

syringe

Water

sander

snow

Procedure:

1. For a vertical seam you will first prep the surface with a nail board so you have a flat surface.
2. Use an angle grinder and in the very center of the seam create a dimple. Continue the dimple upwards towards the top of the seam. Now the flat surface will be shaped like a U. The inside of the U will be the dimpled part.
3. Nail board the second piece of ice you will be freezing to our U-dimpled piece.
4. Place ice together and add water around the edges of the U to tack the piece on (lightly add water). Do not pour water on the top of the seam or through the middle of the U. The top is where you will add water later.
5. Slush the exterior of the U-shape seam to create a dam effect so water can not escape. Allow some time to freeze. Do not slush the top of seam, you will have to pour water down that U later.
6. Once completely frozen go back to the seam and using a syringe add a few drops of water and allow them to freeze.
7. Repeat the process adding water continuously from the top of the U until the seam is filled. Do not fill seam with water all at once, do it slowly allowing the water to freeze before adding more.

Pointers:

• Add water a few drops at a time. Too much water can freeze too quickly, expand and pop your seam.
• Walk away from the seam and work on other projects while each layer of water is freezing inside the U-shape channel.
• Do not slush over your opening at the top, You need that space open for water to be added.
• Temperatures must be below freezing

Advantages

This method works great in extreme cold. When it is so cold that you can not apply aluminum or pour water on the ice due to shattering, this is your only option.
This will create a strong weight baring seam.
This also works great with larger pieces of ice.
Works great for vertical fusing.
Only works in cold weather.