Materials:polyester resin
resin accelerator hardener
waxing compound
painter's tape
pebbles
glass pieces
protective gloves
water pump
3' of 1/2" tube
3' PVC pipe 1/2" and 2"
1/2" PVC cap
1/2" pipe extension bent at 90 degrees
PVC glue
two 1/2" pipe clamps
plastic gutter
2 gutter end caps
plastic adhesive
3' aluminum flashing
3 puck lights
galvanized screws
2 galvanized utility hooks
tar roofing paper
wood stain
varnish
tack cloth
150-grit sandpaper
extension cords
four 6" L-brackets
wood glue
1/2" plywood
1/2" pine
wood veneer
Steps:
1. Build a box out of plywood or any scrap lumber you have available. The box is used as a mold for the resin pour, so it needs to be as big as the desired size of your resin piece. In this case, the bottom of the box is 30 inches by 20 inches with two-inch-tall sides. Since wood isn't water tight, use painter's tape to seal the seams. Coat the wood mold with waxing compound so that the resin board can be removed easily once it hardens.
2. Measure out a 1/2 gallon of resin to do a hot pour first. (Note: A hot pour sets up very quickly to make a harden shell.) Carefully pour the resin into a plastic container and add 18 drops of accelerator. Mix for about two minutes to assure the consistency of the mixture. Pour the mixture into the mold and spread out evenly with a spatula, a thin strip of wood or a paint stick. Let harden.
3. Mix another batch of resin with the hardener and pour a layer on top of the hardened first layer. Spread out evenly. Lay desired pebbles and glass into the resin and let harden.
4. Remove the box from around the hardened resin piece. Drill a hole in the two top corners,
approximately one inch from the top and six inches from either side.
5. To build the frame for the fountain, cut the pine to size.
Top:
8" x 36" (mitered 45 degrees on both ends)
two 8" x 6" (mitered 45 degrees on one end)
6" X 36" wood strip
Bottom:
6" x 36" (mitered 45 degrees on both ends)
two 6"x 6" (mitered 45 degrees on one end)
6" X 36" wood strip
5. Glue desired veneer onto cut boards by applying glue to the surface of the board and the back side of veneer. Clamp it with another board overnight before cutting. Sand and stain as desired. After stain is completely dry, lightly sand, using a tack cloth to remove dust. Apply a coat of varnish. Repeat this step for any additional coats of varnish.
6. Nail the boards together to create a top and bottom box that will house the light, water pump and resin board. (Note: Don't use the 6x36 wood strips yet.) Line the inside of both boxes with tar paper so that they are water resistant.
7. Drill a hole big enough to fit the plug for the pump into the back centered area of the 6x36 wood strip for the top box. Screw the utility hooks into wood strip of the top box in alignment with the holes drilled in the resin board. Attach the 6x36 wood strip in the middle of the top box to divide it into two shallow boxes. The bottom half of the top box holds the puck light, which are screwed into the bottom of the wood strip.
8. Drill a row of five or six small holes two inches apart in the middle section of the PVC pipe. Glue a PVC cap to the other end of the pipe to contain the water. Attach the 1/2-inch PVC pipe into the inside front piece of the bottom box with 1/2-inch pipe clamps on each end. Attach a piece of aluminum flashing with galvanized screws to the top wood box, under the pipe, to guide the water from the pipe to the resin board. The top half of the top box is used to hold the extension cords to plug the lights and pump into.
9. Attach the second 6x36 wood strip into the bottom of the bottom box. Cut the plastic gutter to fit inside the bottom box. Glue two gutter ends tightly on either end so that it holds water. Once the glue is dry, fill the gutter with water and completely submerge the pump inside. Connect 1/2-inch tubing to the pump and pull it up behind the resin board to connect it the 1/2-inch PVC pipe with a pipe extension.
10. Attach the top and bottom box to the wall with L-brackets. Cut a two-inch PVC pipe in half vertically and paint both sides the color of the wall. Place the tubing and electric cord to the pump (heading upward) and extension cord (heading downward) inside one half and attach it to the wall behind the resin board. Attach the other half below the fountain to hide the extension cord from the fountain to the socket.
11. Hook the resin board onto the utility hooks in the top wood strip. Plug in the extension cord.