Making the Black Wall was a mammoth operation, but having made a complex CAD model with every element designed with minimal tolerances, we had allowed for most eventualities. We even allowed for the thickness of glue in the many hundreds of laminated layers.
The curved features were sectioned in the CAD model, and the profiles CNC machined in 60mm thick Beech Plywood. Holes provided location between the laminates using dowel rods. We used a black stained Wood Glue so that you can't see the joins between the laminates. Once assembled, the surface was sanded smooth and sprayed with black Wood Stain. It was then spray coated with 6 coats of clear Polyester lacquer. This was then sanded smooth and a final top-coat of hard wearing clear Polyurethane Lacquer applied. We built a heated tent in the workshop, to extend the spray booth to accomodate the large pieces and to dry the resin quickly between coats.
The pieces were carefully wrapped, with a steel support structure, and lifted through the first floor window by crane. We built a computer model of the window to be sure the large sections could be lifted through. The pieces were then 'hung' on a sturdy pre-built structure, which was stepped away from the brick work, allowing for a narrow crawl space to access the services hidden behind.
We also made the fireplace itself. A mould was constructed from CNC machined profiles, and cast in Jesmonite and Fiberglass. This was then surfaced in lazer cut black polished stainless steel.