Today I started working on the structure of my sideband. I will be making it from Altraform (Douglas and Sturgess: Altra Form, Medium, (43"X 55") using hot water and a heat gun to block it into shape. First I have to choose a block. I have several top hat blocks to choose from, many of which I have carved myself. I carve my blocks from blue foam that I get from a taxidermy supply house (http://www.mckenziesp.com/BS36-P20349.aspx). I use hand saws, a rasp, and sand paper to make the block.
I decided to use this block. I like the classic proportions, and since I carved it myself I can refine the size to be perfect for this project.
After reducing the size of the block and smoothing out any imperfections with sand paper, I cover the block in foil. This will help protect the block and prevent the Altraform from sticking to it during the blocking process. Smooth out the foil with the back of a plastic spoon and mark the quadrants on the side of the block.
The Altraform is cut into a parallelogram. The short sides are on grain with the material and the longer sides are at a 45 degree angle to grain. (on bias) My block measures 29" around the tip and 23" at the base so I split the difference and measure 26" + 3/4" seam allowance. My sideband will be no taller than 8" so I draw a perpendicular line 9" away so I have a little extra to work with.
Altraform can be shaped using a heat gun or hot water between 140 and 160 degrees Fahrenheit. It will stick to itself and almost everything else except metal, glass, and latex. When working with a heat gun I keep a small container of water to dip my hands into. This helps keep my hands from sticking while I work.
I have made another video detailing all the steps in forming the sideband. (no sound)
Coming up next...
Making the tip and choosing a fabric.
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