ONE: FORMING

• A semi-circle knockout creates the curved interior of the fire pit.
• Trace the semi-circle onto the plywood and cut the shape out with a jigsaw.
• Cut out one piece for the top, and one for the bottom. Vertical slats are used to create a skeleton that will be faced with masonite and laminate.

Step 2 – Secure the Masonite Facing

• Begin to screw a layer of 1/8″ masonite to the vertical slats. Countersink the screws.
• Trim the ends flush with a jigsaw after the masonite is secured.

Step 3 – Attach Masonite

• Attach a second layer of masonite using contact adhesive and clamps. This will cover any support screws from the first layer and provide a solid surface for the final layer
• Trim the ends flush with a jig saw once the masonite has been secured using the contact adhesive.

Step 4 – Attach Casting Surface

• Use contact adhesive and clamps to glue on a final layer of melamine, plastic, or laminate.
• Trim the last layer flush on both ends once secured with the contact adhesive.
• This will be the casting surface, and any imperfections here will show in the finished piece.

Step 5 – Build a Box

• Cut the baseboard to size and cut 5 wall sections.
• Mark the location of the knockout and assemble the wall sections opposite the knockout.

Step 6 – Secure the Knockout

• Screw the knockout in place, making sure it’s centered on the baseboard.
• Install the remaining wall sections.
• Clean the form with denatured alcohol before sealing it with silicone.

Step 7 – Seal the Form

• Caulk the edges of the form with 100% silicone.
• After the form is sealed and the silicone has cured, it’s ready for casting.