shaped tree structure

I got the tree structure all shaped today! I like the new shaping technique I figured out. I think it will work well when the candy is put on. It better because I’m stuck with it now. It was hard work to get the shaping finished and I felt like I was on the verge of getting a blister on my thumb to I did the last bit wearing a leather gardening glove. I hate to admit it but I’m getting a cold so I’m not sure how much more I’ll be getting down in the next few days.

Partially shape tree structure

This afternoon and took the tree out in the back yard and started the shaping phase. I though I’d be able to use a saw to take down some of the ridges but it didn’t work very well. The next ridge was getting in the way. So I ended up doing the scrap method, with a chisel. I got the ridges knock down most of the way but there is a lot more work to do to get the shaping right. Towards the end I was experimenting with how to use the chisel and came up with a twisting sort of stroke that leaves an interesting and uneven surface that I think I like. The tree will have a simple cone shape but I don’t want it to look too sterile and I think this method will help.

With Bill’s help we got the structure of the tree all put together. Yeah! We ran into a few snags but we go through them all. First Bill couldn’t fine his jig saw so we had to cut the plywood base by hand. I had to make three trips to Lowes to get things. First the plug I got for the end of the pvc pipe didn’t fit inside the pipe because it was the same side. So I went to find the right size. I couldn’t see one so I got a coupler and that fixed that problem. Next the 1″ bolt I got was too short. By the time we got all the layers – metal plate, washer, plywood, pvc plug and two more washers there wasn’t any bolt at all to put the nut on. So I went and picked up a 2″ bolt. After we got the support system all assembled we started gluing together all the Styrofoam tree parts. Then we ran out of liquid nail on the last big piece to stick together. So I made one last trip to Lowes.

assembled tree structure

 It feel so good to have this phase of construction done. Bill is happy with how the support system worked out too. Now I should be able to do the rest of the project without any help from Bill. Next week I want to get the tree to its final shape, insert the Christmas lights and paint the structure. If possible I’d also like to rough in the large objects that go under the tree.

This afternoon I went to Lowes and purchased a 2″ x 4′ x 8′ sheet of Styrofoam, two tubes of liquid nails and some hardware to attach the tree to the base. This evening I spent about an hour and a half cutting the Styrofoam with a hand saw into tall triangles to form the structure of the tree. The largest triangles are 48″ tall and 24″ wide at the base. The next size was 40″ tall, then 32″ etc. until the last one was just 10″ tall. There are two triangles of each size plus one that is cut in half to fit around the pvc pipe that goes up the center of the tree for structural support. I glued the two halves of the tree together with liquid nails and bamboo skewers to help hold everything in place while it dries.

two halves of tree structure

Tomorrow I hope to get the base cut and assemble the tree structure the rest of the way. I hope to get Bill’s help on some of this because he is a much better engineer than I am and it is important that the structure is very sturdy. Things get heavier than you think when you get all that candy glued on.
I actually enjoyed the process. It has been 3 years since I made a candy creation on this kind of scale.