HOW TO MAKE: Epoxy Police Badge wall decor
Today we will make a police badge, casted in epoxy river wall decor!
- Police badge (this one is the hardest to obtain)
- Oak slab
- Epoxy pigment
Step 1: Removing the Bark From the Slab
We start off by removing the bark from the oak slab using a chisel!
Step 2: Smoothen the Live Edge With a Flap Disc (angle Grinder)
Using an angle grinder with a flap disc, we smoothen the live edge! Make sure all the bark is removed after this part of the build!
Step 3: Create the First Half of the River (track Saw)
Using a track saw, we create the first half of the river.
Step 4: Create the Second Half of the River (table Saw)
After removing the first half of the river with the track saw, we now have a straight edge. Place this straight edge to the fence of the table saw to remove the second half of the river.
Step 5: Using a Stop Block, Cut the Halves to Size (mitre Saw)
At the mitre saw station, we use a stop block to cut all the pieces to exactly the same size. In this build I will be making 3 river wall decors with 3 police badges, so in total I need 6 halves.
Step 6: Mix & Match
Lay the pieces on the ground and figure out which pieces fit best with each other.
Step 7: Flatten the Parts (planer)
Using a planer, we flatten the parts so they are all at the same thickness.
Step 8: Making the Mold
Using some scrap pieces of plywood, we make molds for the pieces to fit in! Make sure to take the dimensions so that the pieces fit snug in the mold.
Step 9: Mix Up a Little Bit of Epoxy to Seal the Edges
Using a bit of epoxy we seal the live edges. This ensures the wood won't release bubbles when the epoxy is casted inside the river.
Step 10: Adding the Pieces to the Mold
Place the pieces in the mold and make sure the mold is level. This way when the epoxy is casted, you ensure it won't overflow on one side!
Step 11: Mix Up Epoxy and Add Color Pigment for the First Pour
The river will be poured in two sessions. The first layer will be colored. The badge will be added and the second layer will be transparent, so that the police badge will lay on the colored layer.
Step 12: Pour the First Layer
Pour the first layers. As you can see I have used 3 colors. Fully transparent, black and blue.
Step 13: Press in the Police Badge
Before the frist layer of epoxy is fully hardened, press in the police badge.
Step 14: Cast the Second Layer of Epoxy
The second layer of epoxy is transparent. This way you can clearly see the badge through the epoxy!
Step 15: Remove the Piece From the Mold
When the epoxy is completely cured, you can remove it from the mold.
Step 16: Cut the Piece to Size
3 More Images
Use the track saw to make the first cut to use as a reference point. After this use the fence of the table saw as a guide for the freshly cut side to cut the piece to the desired dimensions!
Step 17: Routing Edges
Rout the edges the way you want. I left one piece as is, one got a round over edge and one a chamfered edge.
Step 18: The Tedious Task of Sanding
After this comes the tedious task of sanding. We are going to sand the piece from 150 grit all the way up to 2000 grit! Everything above 1000 grit is wet sanding.
Step 19: Polishing
After hours of sanding, you are NOT done! Apply your polishing compound to the epoxy and use a car polish machine with a polish pad (sponge) to polish the epoxy until shiny!
Step 20: Finishing
Almost done! Apply the finish! In this case I used danish oil. Rub it in nice and remove any excess if necessary. Apply multiple layers, I recommend about 2-3.
Step 21: Get Your Little Helper to Put It in a Box
Almost done! Well, the project is done, now we have to put it in a box and go and gift it to the police!
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