So since a healthy business relationship had been maintained between iNViDiA and "Peabody Interior's" ever since the massive "BRAUN" job, "Peabody Interior's" soon came to Ken and Aaron with an order for a custom mantle piece that they could display in their show room! Not exactly something to scoff at, considering Peabody's notable reputation here in Milwaukee. Knowing this, Aaron and Ken were all ready to throw down their expertise in making the best possible Mantle for our friends at "Peabody Interiors," and as comes with the territory, iNViDiA was prepared to apply the highest standards of aesthetic, and attention to craft, in order to get the job done, and create an absolutely exceptional product- after all, we knew that our pal "little Jose," would expect nothing less of us.
Here, we see Aaron inspecting the new molds delivered to us, by our newest mold-maker JUDE! I'll get a picture and properly introduce everyone when I get a chance, but for the moment, you'll have to trust my word in saying he's one helluva good guy. Not JUST because he's one of the few people I know who is truly as excited by mold making as me (although that doesn't hurt my opinions of him I will admit), but because he's just an all around good guy- isn't that worth anything any more?! Not only did Jude effectively produce the molds we needed for this job- in a timely fashion I will add- but he was also responsible for laser-cutting the custom metal emblem that was put on the front of the mantle. iNViDiA is always striving to work with masters of many trades, as it brings allot more perspective to the creation of a product.
Although somewhat skewed of an angle, we can see where the plated metal emblem is adhered to the inner-front of the mold. As mentioned, Jude helped us with the emblem, as well as the challenge of creating the unconventionally shaped mold itself.
Not quite what you'd typically call photogenic, but I suppose it'll do... The odd look of intrigue on Ken's face can only be explained by a temporary brain aneurysm, and as I look more and more at this photo, It becomes easy to imagine it coming onto "America's Most Wanted" at some ungodly hour. "Say, aren't those the fella's that designed our outdoor kitchen?"
The flat top of the mantle, needs to essentially, remain flat- In case you couldn't have gathered that yourselves; this is why so much time is spent on working the concrete until it is no longer workable any more. Since the finish of this particular project, is intended to remain inherently natural to concretes properties, it is important to have an especially accurate viscosity when pouring, and to spend as much time as possible in smoothing out imperfections in the initial pour. In this situation, not much time is spent grinding in the post-pouring process.
So here are the columns, and the column tops that will eventually support the remainder of the mantle piece. Everything is set up before installation, so we can make sure all of the edges are flush, and all the measurements are precise. Why? Because that's just how iNViDiA Design rolls fool!
So for this project, and the likeness to a classically designed mantle, there will be no surface treatment that takes place chemically, and virtually no work is done after de-molding the forms. That does not mean however, that Aaron won't spend hours tooling and tweaking the pieces until they finally and neurotically meet the expectations of himself and Ken. One time, a piece came out perfect after we de-molded it, and Ken and Aaron made me whack it with a sledge-hammer purely so they could try and make it perfect again... I'm telling you, these guys are nuts!
Here's the majority of the mantle pieces all loaded into the back of the truck, and ready to go. Moving and installation are among the most difficult parts of working with concrete, and it takes some serious man power to get a big job put together. Good rules of thumb, are "the more the merrier," and, "the bigger the better," when it comes to moving and installation. Come equipped with plenty of pink foam, and muscle relaxer, to make sure things run smoothly!
So along with the fore-mentioned needs for moving and installing concrete, it will also save you allot of leg (and back) work, to bring a good sturdy cart, roller, or any other such "device with wheels" to help with the moving process. If you don't have a standard cart or roller, you can always improvise by using a skateboard, a magician who specializes in moving large objects with his mind, midgets in roller skates, re-appropriated shopping carts, wearing roller skates, or, what I personally recommend, Carl Hoenisch. Its worth mentioning that Carl is also a wonderful- and ever so cordial- bouncer if you need an enormous dude to watch the door for you. See, I told you iNViDiA is always looking to work with multi talented individuals... He gives wonderful back rubs too, but don't tell him I told you!
So here is some candid photo's of Ken and Aaron REALLY loving concrete...
... When people desperately struggle to move incredibly heavy objects in front of me, the last thing I think to do is help them out. Instead, I take pictures of them grunting, and trying, from angles that compromise their integrity, and make it seem that they are sophomorically humping concrete. And you know what dammit? I wouldn't have it any other way!
And there you have it!
We weren't too thrilled about the wall that was exposed upon raising the mantel, but Peabody assured us that it would be plated with sheet metal. All in all it was a rewarding experience the second time around as well, and it just goes to show you how crucial communication is!
Here, we see Aaron inspecting the new molds delivered to us, by our newest mold-maker JUDE! I'll get a picture and properly introduce everyone when I get a chance, but for the moment, you'll have to trust my word in saying he's one helluva good guy. Not JUST because he's one of the few people I know who is truly as excited by mold making as me (although that doesn't hurt my opinions of him I will admit), but because he's just an all around good guy- isn't that worth anything any more?! Not only did Jude effectively produce the molds we needed for this job- in a timely fashion I will add- but he was also responsible for laser-cutting the custom metal emblem that was put on the front of the mantle. iNViDiA is always striving to work with masters of many trades, as it brings allot more perspective to the creation of a product. 
Although somewhat skewed of an angle, we can see where the plated metal emblem is adhered to the inner-front of the mold. As mentioned, Jude helped us with the emblem, as well as the challenge of creating the unconventionally shaped mold itself.
Aside from the rounded fronts of these pillar caps, nothing too out of the ordinary happening here. A styrofoam core is used in this piece, to save us some weight, as well as material waste, and unsurprisingly, the good folk at Peabody's wanted the same charcoal tint to their concrete mantel, as was used at "Ryan Braun's Waterfront." After de-molding the form, we then re-assemble the same mold to make our second piece- another way to save from unnecessary waste. YAY TEAM!!!
Ken, Aaron, and some unshaven heathen are doing what they do best- mixing and pouring concrete!!
Not quite what you'd typically call photogenic, but I suppose it'll do... The odd look of intrigue on Ken's face can only be explained by a temporary brain aneurysm, and as I look more and more at this photo, It becomes easy to imagine it coming onto "America's Most Wanted" at some ungodly hour. "Say, aren't those the fella's that designed our outdoor kitchen?"
The flat top of the mantle, needs to essentially, remain flat- In case you couldn't have gathered that yourselves; this is why so much time is spent on working the concrete until it is no longer workable any more. Since the finish of this particular project, is intended to remain inherently natural to concretes properties, it is important to have an especially accurate viscosity when pouring, and to spend as much time as possible in smoothing out imperfections in the initial pour. In this situation, not much time is spent grinding in the post-pouring process.
So here are the columns, and the column tops that will eventually support the remainder of the mantle piece. Everything is set up before installation, so we can make sure all of the edges are flush, and all the measurements are precise. Why? Because that's just how iNViDiA Design rolls fool! 
So for this project, and the likeness to a classically designed mantle, there will be no surface treatment that takes place chemically, and virtually no work is done after de-molding the forms. That does not mean however, that Aaron won't spend hours tooling and tweaking the pieces until they finally and neurotically meet the expectations of himself and Ken. One time, a piece came out perfect after we de-molded it, and Ken and Aaron made me whack it with a sledge-hammer purely so they could try and make it perfect again... I'm telling you, these guys are nuts!
Here's the majority of the mantle pieces all loaded into the back of the truck, and ready to go. Moving and installation are among the most difficult parts of working with concrete, and it takes some serious man power to get a big job put together. Good rules of thumb, are "the more the merrier," and, "the bigger the better," when it comes to moving and installation. Come equipped with plenty of pink foam, and muscle relaxer, to make sure things run smoothly! 
So along with the fore-mentioned needs for moving and installing concrete, it will also save you allot of leg (and back) work, to bring a good sturdy cart, roller, or any other such "device with wheels" to help with the moving process. If you don't have a standard cart or roller, you can always improvise by using a skateboard, a magician who specializes in moving large objects with his mind, midgets in roller skates, re-appropriated shopping carts, wearing roller skates, or, what I personally recommend, Carl Hoenisch. Its worth mentioning that Carl is also a wonderful- and ever so cordial- bouncer if you need an enormous dude to watch the door for you. See, I told you iNViDiA is always looking to work with multi talented individuals... He gives wonderful back rubs too, but don't tell him I told you! 
So here is some candid photo's of Ken and Aaron REALLY loving concrete...
... When people desperately struggle to move incredibly heavy objects in front of me, the last thing I think to do is help them out. Instead, I take pictures of them grunting, and trying, from angles that compromise their integrity, and make it seem that they are sophomorically humping concrete. And you know what dammit? I wouldn't have it any other way!So after the unflattering concrete-humping session has gone on long enough, and I've been punched in the face enough times to stop laughing and snapping photo's, the crew finally gets the final places in order, while making sure that everything is exactly where it needs to be.
Here's a nice detail shot of the J.C. emblem that we embedded into the concrete with the help of Jude and his magical laser cutting powers! The lines carved in are an especially nice touch, and are meant to look like a classical "keystone" that you might see in older mantle designs, but I'm sure you all knew that already anyhow...
So here's what we THOUGHT was a final installation shot of our tentative mantle piece, but of course, things are never as simple as they seem...
... And here's what the guys THOUGHT would be a nice little crew photograph, taken after we finished that day.
We were all very pleased with the final outcome that day, but as it turned out, our pals at Peabody decided they needed the mantel to be elevated another ten inches or so...
Understandably, these things happen, so when Peabody informed us of the change in design, we got right to it, and a few days later, had molds made to work as raisers. I cannot say anyone was enthusiastic about re-installing, but its all in a days work right?
And there you have it!
We weren't too thrilled about the wall that was exposed upon raising the mantel, but Peabody assured us that it would be plated with sheet metal. All in all it was a rewarding experience the second time around as well, and it just goes to show you how crucial communication is!
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