I scarfed up a set of 4 fluted columns for my deck off of craigslist a while back (yay!) But, they didn't come with capitals (boo!). Finding the prices for capitals of the size I need to be kra$y, I've decided to try to make them. I think I've got most everything figured out, except for an important detail. I need to build 8 (front + back) volutes. Which is basically just the scrolly-looking part of this (http://www.fotosearch.com/ECC116/01030018/). Roughly 26" X 11" and ~ 1 1/2" thick. Luckily I have 4 columns with capitals like this from which to copy. The detail not obvious in the drawing is that the "flat" part of the scroll isn't flat but dished out round about 1/2" deep at the deepest and, of course, gets shallower as the gap gets narrower. I assumed I'd hand or rotary carve this detail until I actually tried to…granted I tried in a pine scrap, but it taught me that I have no where near the patience or talent necessary to do 1 this way, much less 8 - at least not without cringing every time I walk by them. So, I'm looking for cheating suggestions. Since it will be painted after all, my only thought is to create a pattern of the volute, route out the "gouge" 1/2" deep and square edged, and fill back a dished gouge with bondo wood filler. Then shape and sand the bondo since (I think) it will be easier to shape than any wood because there's no grain to deal with. I did one sample this way (except I didn't go a full 1/2" deep) and found that the bondo was still very hard to sand which resulted in rounding the wood detail wherever I didn't want it. So, not a perfect solution. Less hardener in the bondo will give me longer working time, but still, shaping it is tricky and I have no tricks up my sleeves. Before I go whole hog on this, I thought I'd stop and ask for advice from the experienced folk here.
Is bondo the right choice? Is there something else easier to work and still weather-resistant once painted? Or is there yet another way to do this I'm not thinking of?
Is bondo the right choice? Is there something else easier to work and still weather-resistant once painted? Or is there yet another way to do this I'm not thinking of?