
There are a lot of challenges to fabricating this part. First of all, there is no 16ft long sheet, and if there was, there are not too many 16ft long ovens to heat it up! So the fabrication method is to form 2 pc, and then chemically bond the 2 sections with liquid acrylic resin. That bond is almost as strong as the sheet itself.
Cutting the toprail is another challenge as the customer wanted one continuous piece. Again, we cut 2 pc and bonded together and then to the "wall". It takes a lot of practice to use this adhesive and achieve bubble free bonds - which give the appearance of 1 cont

But wait - now that we have created this 16ft monster, how do we get this out the door and in the backyard of the customer? Even though the destination was 30 miles away, packing for transport was intricate: we had to completely support the entire piece underneath - and put this on a custom pallet. At the job site it took 8 people to carefully lift and place it in the final position.
Pretty cool! Make sure you Click to Enlarge this picture.
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