Two large blocks
The work on the on copy of the statue of Thomas Aquinas has finally started. I had received two large blocks of Udelfanger sandstone some time earlier: one destined to make two angels out of it and one block from which I had to carve the two parts of the statue of St. Thomas from St John's Cathedral in Den Bosch and fit them together. So the first step was to divide both blocks into two with the diamond chainsaw.
After that I put one block on my copying saw and started presawing Thomas' lower half. The dividing line of the two parts was meant to be near the line of his hood, so that this almost invisible. Reminder: in an earlier post I wrote that the old statue was made from a single piece of stone, in which the layers run vertically. Because it's more desirable that the layers run through the statue horizontally (in that case, there's less chance that an entire big slice comes falling down at once, after weathering) it will be different in this copy. But the quarry has no banks in which the stone is higher than 120 cms. Therefore, the head was to be made from a separate piece.
Because of the large color differences between separate blocks of Udelfanger sandstone I was sent a very large block from which I had to cut the two parts. From this I made the body and the head of Thomas.
Fitting together of the two parts
Then, the two pre-sawn parts of the head and body had to be made to fit to each other snugly. That wasn't so easy, because the dividing line doesn't run straight. It follows the wavy line of the hood and needs to be higher at the right hand, because otherwise the joint seam would run through the knuckles. These inclined faces need to fit together well. For this, it should first be clear what will be located where, and for that I needed to rough carve the two parts for quite a ways. I carved the upper body and the lower body so that I could see where it all would be going, and I could see where the dividing line was to run. Then I could find the joint surfaces.
Because I made this joint line visible on both pieces, I could demarcate the joint surface and carve away the excess stone. By keeping on fitting the pieces together and scribing the excess stone, I could ultimately achieve a tight seam. When the fit was tight enough, I scribed off where I wanted to put the stainless steel pins and drilled four holes. Two holes in each piece, so I could adhere both parts with strong epoxy glue and two thick threaded rods. Also, the joint plane itself was bonded with a suitable breathable mortar. You should actually never make a horizontally extending closed off gluing surface on a statue sitting outside. The stone above such a dense glue layer can't lose its moisture and will start to rot right above the glue seam.
My colleague Serge had an commission in Udelfanger sandstone as well for St. John's Cathedral in Den Bosch. He was asked to copy this angel. He had previously made one and asked me if I wanted to saw this one as well. So, here goes.