How we made the Pepper Sink – Blair’s Hot Sauce Custom Sink

Trueform Concrete recently created a custom hot pepper sink for the Blair’s Hot Sauce, located right here in New Jersey.  If you are a fan of amazing  hot sauces and hot snacks, you probably know Blair’s work.  This guy brews up some seriously hot, and delicious tasting stuff for their operation.  Check them out @ at: Extremefood.com

With input and assistance from the client and the designer, Kim Suchodolsky of Design Alternatives, we were able to bring this themed sink design to life.  Together, we created something unique and fun using a process known as GFRC, which allows concrete fabricators to create more complex and precise concrete work.

For those of you out there that think making concrete is easy, we documented only a little bit of the of the important steps to creating the pepper sink to give a real account of what it takes to make projects like this happen.  So here is a behind the curtain look at how we did it.

Blair's Sauces and Snacks

Blair’s Sauces and Snacks Logo

Sink preparation

The inspiration for the sink and the rendering that would be transferred to a production mold

scaling the sink

Reversing and grid scaling the sink to constrain proportions for proper scale and size.

Sink shape transfer

Transferring the shape and the real size to wood and cutting a shape master for the mold

Sink shape master

The sink shape master after it was cut

creating elevation

Creating basic elevations and 3D contours for sink

Creating the sink body

Creating the sink body and shape with foam.  This was a new idea from our shop manager and it worked really well as a base structure

Carving the sink

Carving the sink shape with the Turkey dinner special – Never did this one before…but it worked perfect!

Shaping the sink

Precision poultry carving technique is exhibited in this photo!

Covering with fabric

Covering the prepared mold with fabric to hold the form and create smooth curve transitions

Covering with fabric

Covering the prepared mold with fabric to hold the form and create smooth curve transitions

Fiber Glass covering

Fabric was covered with fiberglass resin to create a hard outer shell to work from

Forme the sink

Sanding and filling with Bondo many time over to create a perfectly smooth and clean surface for the gel coat to sit on

Gel coat

The sink is gel coated to create the strong outer shell that we cast against.

sink in mold

The sink mold is placed and caulked into the project form

tape off sink

The sink is perfectly tapped off creating the separation between the red and the grey face coats

spray GFRC

Spraying the grey portion of the face coat on to the form and around the sink mold

remove taped section

Carefully removing the taped section to expose the sink mold so that the red face coat can be sprayed

Shoot the red

Shooting the red colored face coat on the sink mold

Spray GFRC

Shooting the red colored face coat on the sink mold

Scratch Coat

Creating the bonding surface for the back coat to the face coat of the GFRC

wet down

Wetting down the surface with water after we de-molded the project the next morning

sink

Wetting down the surface with water after we de-molded the project the next morning

Final sink installed

This is the pepper sink installed

By having a behind the scenes look into what it takes to make a custom project, we hope that you can appreciate the amount of time and craftsmanship Trueform puts into their projects.  Remember that this leaves out out the hundred other steps that the project goes through fromm the template to the installation.

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