I’ve been asked to build a new cross for a local church, aprox. 3′ wide by 5′ tall and 5 inchs thick. It will sit about 40 ft, in the air on the peak of the roof. Subject to New England weather. I’m thinking, 3/4″ MDO plywood build up, stainless screws and a high grade yellow glue. Maybe cap with copper flash to keep the water off. Any ideas on something more durable?
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Have a metal fabricator build it out of aluminum.
I don't have anything intelligent to offer but I just wanted to say you have a clever title for this thread.
You read the titles of these threads and you never know what to expect.
Good luck with your project !
I'm with the previous poster about making it out of metal. Anything wood is likely to be A) heavy and B) subject to the weather. However, if you do build it from wood you'd probably be better off building it hollow, maybe with cedar or treated plywood.. something that will withstand the elements.
Are you also responsible for mounting it?
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Copper would look sweet.
Wood's going to be heavy and prone to failure.
On the other hand metal is going to attract lighting.
I have nothing of real intelligence to offer.
Post a picture of the final product
Why not try for some IPE?
if it's going to be white....i'd wrap it with Azek
This is what came to my mind.... although Piffin let me know that they may be something more specific to my geography.... I've used them for other stuff and feel they are very durable.
hmm i was going to suggest ipe too, but that is going to be one heavy mother... What about carving the cross out of polystyrene and then wrapping it in fiberglass and epoxy, and then just picking a really good durable paint... no conductivity, light, and strong...
westsystem epoxy has tech guys that will talk you through just about any project... they didnt bat an eyelid when I wanted to mount an eyebolt in a bowling ball with 300lbs pullout strength...
http://www.westsystem.com/
Ok , sorry for the detour (this ain't the coolest, crosses and all, ya know) , But I gotta know more about this bowling ball stuff.
they didnt bat an eyelid when I wanted to mount an eyebolt in a bowling ball with 300lbs pullout strength...
http://www.westsystem.com/
I needed a really heavy bob to hang from the ceiling in my classroom to do the whole touch bob to nose, let go watch it swing the length of the classroom and then have it come all the way back and almost touch the nose trick... it is REALLY scary to see the bowling ball hurtling back at you... which is why I made sure that adhesive holding the eyebolt into the bowling ball will be the last to fail... I also use it as a heavy thing to show kids about mechanical advantage too...
jmmmm
think i'd go for metal and have it powder coated... if it's the highest thing in the area... i don't think lightning will care if it's metal or wood...
alum welded and powder coated... might be the fastest, cheapest, best...
p
Seems like regardless of what it is made of a lightning grounding system would be prudent....
No worries. Lightning won't strike a cross. :)
If you go with aluminum;
I used to make artist panels out of aluminum the way to do it is with "Hysol glue" A two part epoxy that cures at room temp.
Sand both surfaces with 80 grit then wipe M.E.K. (Illegal in some states )
then glue one surface and clamp. One thing to point out, it's not wood. Not about pressure so much as thoroughness, I mean lots of clamps.
Long cure time ( five days by the book)
Watch for creeping as it cures.
Good luck
p.s.
You can find it in the "Wick's Aircraft Supply" Cat.
Redwood. Looks rich and it's durable. If you do go the MDO route I would not use yellow glue. IMO Gorilla glue would be better.
I had an idea for a cross a few churches back. You could see the cross from the highway and they wanted to light it but it was steel and absorbed all the light.
I thought if you could cap the cross with the material they use for highway signs it would be extremely reflective and weather restistant. I think they make it with an aluminum backing. You'd have to be carefull with it if you were fastening it to steel though.
I like the idea of the cross shinning in the night. Kind of a beacon.
If you are thinking of including internal lighting, have you given any thought to fabricating the cross of half-inch translucent acrylic?
This material would be both structurally sound as well as weather proof.
A PE cell would take care of the electrical switching duties.
You might be surprised at savings over the project.
Lapun.
I like the idea of translucent acrylic. Have you thought about how it would look in the daytime? Lighting it at night is just one of the design considerations you have to take into account. What it looks like in the daytime when people show up for church is huge. I think a lot of these people consider the church to be like their house and they will reject anything that is to outside the norm. What will the neighbors think?
Most people are pretty conservative and if it doesn't look like a "regular" cross in the daytime they will never buy into the idea.
One of the reasons I thought the highway board would be suitable was because it would be white in the daytime. So it would look like a normal cross. But at night it would be easy to light up. The material they put on the board is is just amazing. You hit it with just a little tight and it just pops right out at you. Considerable research and development has gone into this material for highway safety.
Man, you have a problem, and it isn't a technical one. I can recognise the uncertainty of elements within the group who would contest such a concept as 'showey'. The cross, to many, is too sacred a symbol to be treated as a gimmick. To confront such people directly would be to court outright rejection.If the white (or cream) unit doesn't clash with the exterior, you have a good start. I have personal problems with an unpainted galvanised pipe cross adorning a new Baptist church in my area - it looks too industrial for my sensitities. I have seen the same feature on other churches the same architect has designed.I can only suggest that you present a range of alternatives, and emphasise the silent outreach effect of an illuminated cross. The reference to the influence of the people in the decision-making process is a positive sign. It is obviously a collective rather than an executive decision.I have been in similar situations with a heritage listed church, making necessary changes to the interior fittings. One needs to be both original and traditional in approach - but consultation is the ultimate key to progress.Whichever way it goes, you will have an ally whose opinion will have a strong influence. Be absolutely certain of that!Lapun.
I like the idea of presenting multiple ideas so they can sort through them. In my (limited) experience there is a group of leaders in the church that decide almost everything. And sometimes it's not real clear who they are.
I've never been on the inside of any group I can recall. So my perspective is from the outside looking in and knocking on the door. Sometimes they answer and sometimes they don't.
Our last house was on a county road between two towns so it got a fair amount of traffic. I built a cross about 4' high and put it in a Christmas tree in the front yard. The tree was about 45' high. I built the cross out of 1 X lumber and sealed it with multiple coats of white polyurethane. Then on the face of it I nailed translucent rope lights so it was tightly covered.
I must have had over 300 lights on it. It kind of became a local landmark.
Edited 2/18/2008 6:46 pm ET by popawheelie
when my parish built a new church a few years ago , to replace one ready to collapse, I did the roof.--3 crosses ended up being installed-- they are about the size you are describing.
metal, powder coated white-crane to install
hope the pictures come through--took them on a rainy day-- have better ones taken on a sunny day--but these are already sized for posting on breaktime