The Modeler's Forum

The Delta Mill was built in 1810 in Delta, Ontario and is a National Canadian Historic site.  I am going to attempt to model the mill, which will require me to put my skills to the test!

I will start with the front wall.  The mill's dimensions are approximately 50 feet by 35 feet. 

I started by modelling all the stones (over 2000) in my design program.  Once I had all the stones laid virtually, I laid out the doors and windows.  Once I had everything ready I used my laser to scribe and cut out all the parts.  I did a lot of experimenting with this step.  The photos I am posting are the result of approximately 2 dozen attempts.

Once I have my pattern scribed and cut into wood, I create a box and fill it with hydrocal.  Once dry, I removed the wooden wall jigs and peel away the wall.  There is some residual wood details, which the staining looks kind of good. 

I am in the process of cleaning out the mortar lines and defining the stones.  I am happy with my results.  When I have my wall as best as I can get it, I will cast it in a master model of silicone so that I can make as many walls as I want.

I cut a few windows (12 over 8) and set them into lplace to check for fit. 

Looks absolutely fantastic , well worth the 2 dozen attempts  ;)

Darn good looking walls Joe..... 8) . I'll be looking in.

Hey Joe:

The walls are beautiful. Can't wait to see more.

Karl

Joe,

The wall looks fantastic, I'll be following along as well.

Tom  ;D

This will be interesting to watch, Joe.

Great work so far.

Are you planning on adding the keystones to the corners?

Cheers, Mark.

Joe,
Looks fabulous !!   Wondering if you will be making those walls, windows, etc...  available commercially ??


I would certainly be interested.
Thanks,
--Paul

Quote from: PaulS on February 28, 2021, 12:36:01 PM
Joe,
Looks fabulous !!   Wondering if you will be making those walls, windows, etc...  available commercially ??


I would certainly be interested.
Thanks,
--Paul

I'd be interested, too.


dave

Thanks for having a look and a the positive comments.

Mark - you have a keen eye.  I have debated over those keystones on the corners.  This mill has fooled me a couple of times.  I thought when they did the restoration that they added those.  I found a photo where they pretty much removed the entire corner and rebuilt it that way to reinforce it.  I included an old photo that shows that they were there when the mill was built.  The restoration work is so amazing that what they did not only looks fantastic but it is true to the people who built the mill 200 years ago! 

I will make the adjustments and re-cast the wall ... stay tuned. 

Dave and Paul, I never thought about a commercial project.  I am planning to make master moulds once I perfect my wall sections, so I guess we will see how well I can progress. 

Funny story, I originally started designing the mill to be 60 x 40 because I found an original real estate ad from the mid 1800's when the mill was sold, I think to someone from Scotland.  Imagine their surprise when they discovered the size of the mill was exaggerated and they bought a 50 x 35 mill.  I do love reading and discovering history.

This old photo shows the mill, different windows from the original 12 over. 8. 

Joe, Beautiful Job!!!! I'd be interested, too. Dennis

Very nice indeed.


Jerry

Joe,

This looks to be an interesting project.  I will be following along.

Rich

Nice looking walls Joe

Doug

Hey Joe:

Thanks for post the real pics.

Karl

A quick update on my wall experiments. 
1. I shortened up my front wall section to account for the end walls of the mill.  It still comes out to the 50 feet dimension.

2.  I added the keystones in a similar pattern into the edges of the end wall section.  I only made the end walls about 2 inches wide for this experiment.  The horizontal lines all match up.

3.  I made a mood that creates a pretty good corner wall that wraps around.

Notes:  The wall sections fit really well together and the seam is almost invisible.  You might notice some jigs and fingers holding things tight in lieu of glue for my test fit. Not easy with an iPad and 3 wall sections, lol

Next steps:
1.  Design and cut the doors.
2. Work on the 2 peaked end walls, this will take some time.

Joe

Hey Joe:

beautiful job on the stone walls. Can't wait for more pics.

Karl

Joe nice stone work on those corners.


Jerry

Joe,
Looks like an interesting project.
Will follow along...
Tommy

Thanks everyone, I am working away on laying bricks "virtually" everyday.  Will keep you posted with photos when I have an update.

Please keep us updated.  Very nice work.  Mark

I have been working on the end wall and I finally have a wall section to show.  I kind of figured that not having a couple of stone courses was going to be a structural problem, lol. See the broke wall, so I added 3 courses of stone, you won't see it anyway once the water is modelled.  I am pretty happy with the fit and finish (this is just fresh with no sanding, just a dry test fit). None of the windows are glued in, only shoved in place. 

I think I will do the other peaked wall next.  I can't wait to see what challenges this section will have in store for me.  I am hoping to get the next section done a little quicker.

Joe


Very interesting project, I will be following along. Thank you for sharing it with us.

I was having trouble posting photos that were resized and not upside down.  I think I have it figured out, fingers crossed.  Thanks for having a look. 

Good Morning
Here is the progress of the third wall.  I tried to set my windows and doors deeper into the mild and had trouble getting them out.  You can see the white around a couple of the openings where the hydrocal flaked off with the mood.  I will have to go back to the shallower method I was using.  I have the 2 easiest walls left so it should be smooth sailing ... right???

Thanks for having a look and following along, I appreciate it.

I have finished the short wall.  I made it too tall and it won't work with the way it was built.  I am going to adjust it and make it the same height as the end wall.  I also will experiment with making the wall thicker on the bottom half and thin on the top.  I will see how it goes. 

For now I will be working on all my final adjustments before I am content with the end results, then I will see if I can make some masters so I can make castings for those interested.  Still lots of work but it will keep me focused and headed in a positive direction. 

Joe

I installed all the windows on 2 walls and started to work on the doors as well.  A couple of progress shots.  Joe

Finished placing the windows and the doors.  Next step I will tackle the roof and roof trim.

That is looking really, really good.

That is going to be one good looking mill when you get done Joe.....well done.  8)

Hey Joe:

What can I say but Wowwie. Very nicely done.

Karl

Joe,

Great build and very nice recovery on the broken wall. Looking very good.

Tom  ;D

Quote from: GPdemayo on May 21, 2021, 04:29:07 PM
That is going to be one good looking mill when you get done Joe.....well done.  8)

Thanks Bob, I am pretty happy so far, I have learned a lot with casting hydrocal.

Quote from: GPdemayo on May 21, 2021, 04:29:07 PM
That is going to be one good looking mill when you get done Joe.....well done.  8)

Thanks Greg, each step certainly brings a few new challenges, much appreicated.

Joe

Quote from: postalkarl on May 21, 2021, 04:48:22 PM
Hey Joe:

What can I say but Wowwie. Very nicely done.

Karl

Thanks Karl, always appreciate your words of encouragement.  Thanks for following along, it is a heavy beast when I lift it.  I think of the South River Model Works Roundhouse kit and can't imagine how heavy those walls would have been.

Joe

Hello Joe, what an impressive looking building. Can't wait to see the finished product.   Jeff

Quote from: nycjeff on May 21, 2021, 06:04:11 PM
Hello Joe, what an impressive looking building. Can't wait to see the finished product.   Jeff

Thanks Jeff, I am working at a slower pace but hope to get more accomplished in the next week.

I worked on assembly of the walls and the roof for the turbine shed add on.  The roof is just placed there for now.  Next step is the main roof and trim.  Hopefully, I can pick up the pace a bit, work seems to get in the way of fun sometimes.

Hey Joe:

Looks just great so far. Keep the pics coming.

Karl

Joe


I just got caught up on your progress, beautiful work.  This is really looking great.

Quote from: S&S RR on June 01, 2021, 10:08:15 AM
Joe


I just got caught up on your progress, beautiful work.  This is really looking great.

Hi John
Thanks for following along.  Worked on the roof and trim.  Update to follow.

I installed the trim and roof panels this weekend.  I see from the photos I forgot to touch up the trim, lol. My next step is figuring out the type of roofing.  It would be real simple to throw on the already to install 3 tabs, see photos.  Another option is slate.  I never had slate for any of my kits but I must have had something in the works ... I have quite a few old files and kit ideas, those might be good for a laugh.

Anyway, I took a photos of the sheet, I even lightly scribed on guidelines for laying them down straight.  I coloured them with various prismacolor markers (various shades, 70%, 50%, 40%, eggshell and blending)
and laid them out quickly to get some thoughts or feedback.

Thanks for following along,  Joe

Good pick with the slate roofing.....it goes well with the stone structure.....well done Joe.  8)

Joe,
Your project is looking great !
Nice update photos too...
Tommy

Hey Joe:

Looks just beautiful so far.

Karl

Well, it has been awhile but I have been colouring slates and laser cut a chimney stack.  Hopefully the slates will go quickly, lol

That is just beautiful stone work!!


Jerry

Hey Joe:

Love those shingles. that roof is gonna look just great. Can't wait to see it finished.

Karl

Quote from: Jerry on July 10, 2021, 09:54:47 AM
That is just beautiful stone work!!


Jerry

Thanks Jerry, the hydrocal and laser does all the work!  I am hoping to make some masters this summer, stay tuned.

Joe

Quote from: postalkarl on July 11, 2021, 09:38:58 AM
Hey Joe:

Love those shingles. that roof is gonna look just great. Can't wait to see it finished.

Karl

The shingles are a labour of love, lol.  I am almost done, chimney is installed and will post photos in a day or so.  Thanks

Hey Joe:

You are quite welcome.

Karl

Cool chimney...
Doug

Quote from: NKP768 on July 15, 2021, 10:11:08 AM
Cool chimney...
Doug

Thanks Doug, the chimney is all laser cut, carefully sanded on the corners and glued together.  I think I should be able to do all sorts of cool chimneys with this technique and material.

Almost done the roof!

I have been away from this for too long.  I finished off the roof and have begun working on the base.  I am in the home stretch now and should be able to finish, quickly???
Joe

Very nice Joe. Love the roof coloring.

Thanks for the comment on the roofing ... it takes a long time to colour them but they come together nicely and makes it worth the effort.

Added a few rock piles this week and designed and cut grates for the water ways and a fence on the roadway.  I will finish the grates and fencing if all goes well this week.

Thanks for looking, Joe

Hey Joe:

This is coming along quite nicely.

Karl

Looking really good, Joe.

Love the entrance to the side door.

Cheers, Mark.

the slate roofing looks great Joe.....well done.  8)

Quote from: postalkarl on October 11, 2021, 02:27:36 PM
Hey Joe:

This is coming along quite nicely.

Karl

Thanks Karl, always little thing to finish up as you know too well!

Quote from: GPdemayo on October 12, 2021, 08:56:38 AM
the slate roofing looks great Joe.....well done.  8)

Thanks Greg, I am always surprised at how it all comes togther with my Prisma Coloured Markers.

Quote from: Mark Dalrymple on October 11, 2021, 03:30:15 PM
Looking really good, Joe.

Love the entrance to the side door.

Cheers, Mark.

Thanks Mark, I actually redesigned the hand rail and cut it last night.  I will see if I can't get it all painted and install.  It will look more like the old photos when I am done and matches the hand railing on the other side of the building.

I threw up a couple of fences, installed a sidewalk and laid down a hydrocal roadway this week.

Very nice on all points.  I also like the fence choice at the end--very Art Nouveau in the style of Charles Rennie Mackintosh (one of my favorite architects of the era). A lot of those are still seen around bigger towns and cities but seldom get modeled.

--Opa George

Very nice modeling.