Post #181549 by Palama Tiki on Wed, Aug 24, 2005 5:29 AM

Here’s my latest attempt to capture the Ideal Moai style…

Moondance asked if I would describe my AAC Moai carving process, so here goes..

SAFETY NOTICE: Always wear a cartridge respirator and goggles when working with AAC. It’s very dusty. Wear clothes that you don’t mind getting really cruddy. The dust is insidious.

I sketch the outline on both sides of the AAC block using a cardboard template.

Make the initial very rough cuts with a small handsaw; just a cheap one that you find at Wal-mart or Home Depot.

Also see page 4 of this post (A-A’s post on tools for use on AAC) http://www.tikicentral.com/viewtopic.php?mode=viewtopic&topic=10451&forum=7&start=45

At first it seemed odd to use a handsaw on concrete, but trust me, once you start working with AAC, you’ll quickly figure out how it works and then you’ll start experimenting with other tools. Just remember that the AAC will really dull the blades.

Be patient; at this stage, the carving looks really crappy.

Once the rough cuts are made, I use an angle grinder with a sanding disc attachment to start shaping the carving. I also use the following tools: rasp, chisels, surform or plane, sandpaper (36, 60, and 100 grit). The 36 grit helps in shaping areas that are too tight for the angle grinder. A-A also lists rifflers, etc. that he uses. I use an old butcher knife as a draw knife as well.

When using the chisels, I don’t use a traditional stone carving technique of mallet-on-chisel; the action is more like using a putty knife to scrape paint. That action helps shape the carving.

You can also use a Dremel tool with the stone attachments, which I use to carve out the ears. I’ve also been using that to make AAC tombstones for Halloween decorations. ( I know this part isn’t tiki, but it IS the AAC post :) ). I distress the slab of AAC using hammer, big butcher knife, etc, then sketch out the lettering with pencil.

I then use the Dremel cutting tool guide with a drywall bit set to ¼ inch depth to initially carve the lettering, then I go over the grooves of the lettering with the tapered stone bit to get the depth to the lettering. After that, more sanding and distressing with paint. Coat with clear concrete sealer, and you have some pretty cool Halloween decorations.

Anyway, back to the Moai… once you have the basic shape, it’s all hand sanding from there. Not to sound coy, but it’s really hard to describe; you just have to sand away till you get the subtle shapes that you want. Use the 60 grit to smooth down the rough spots, then use the 100 grit to close the “pores” of the AAC. You’ll notice that with the heavier grits, the pores tend to open up more.

When finished, brush the dust from the carving, and coat with clear concrete sealer, leave as-is, or you can paint with regular spraypaint or Fleckstone spraypaint.

I hope this helps.