Who wouldn’t love working on a Disney project? This was a fun project with characters, castles and great Disney graphics. We just completed our work, delivered to our client they added their magic and it looks fantastic! If you are in Times Square NYC this holiday season check it out.
We started out by vectorizing the clients sketch of a giant snow arch and castle with the “Frozen” logo carved into it. In Enroute Pro we gave the outline shape and texture and designed the accurate dimensions to fit on the store fixtures.Now this arch is about 16′ Wide so we cant cut it all at once. I’ll break up the file and start cutting the pieces.
So to keep the weight down we chose to make the arch out of blue insulation foam. We started by gluing 4’x8′ sheets of 2″ foam together. Our arch will end up 8″ thick. Once glued we are ready to cut.
Once the panels are cut – we cut out a channel on the back to set the PVC piping wich will hold the pieces together. The PVC is set in place and the safety cables are installed and crimped.
The adhesive is applied and the sides are assembled.
Now we’re ready to tackle the bases! These need to be large solid pieces of foam so we cut them in discs that will sit on top of each other then Brian will come in with a sawzall to rough sculpt it. Here you can see Eddie assembling the discs and gluing in place.
We’ll finish up the other base and start sculpting. Brian got out the sawzall for the rough cuts then the belt sander for the second go around.
Mark and Kevin doing some finishing sanding.
Here’s Brian and Greg with their homemade sanding tool – Great for taking away a lot of foam fast.
Ready for Bondo and Paint!
While the arch is off to the paint shop we’re busy printing away and building some other cool features for the install.
Here is an 8′ Marquee Gift Tag.
A GIANT painters pallete.
Lots of wrapping paper….
Some cool Mickey Ears….
and a bunch of other cool stuff.
And here is the transformation (with the help of our clients amazing design and installation skills)