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Step #1: We start by welding an aluminum frame around the cart and creating a "box kite" frame for the canopy.

Step #2: We need to sculpt up the leaf pattern in wax first. Then we make a mold and cast the plates in Urethane.

Step #3: Next we have to lay up the frame in High Density foam. This is what we use to sculpt the final shapes into. As with most projects, they have to get ugly before they can get pretty.

Step #4: We sculpt the "logs" that will form the supports for the canopy.

The client sent us 4 standard rotocast beverage carts - Our job was to turn them into large fruit for the folks at Tropicana. When we were done the carts were sent to Time Square in New York city for a sample promotion.

 

Step #5: Hours of sanding and finish work. When we get them done, we apply several coats of special resin and paint.