Ornamental plaster restored
Washington, DC

finished plaster moulding
old moulding removed
Moulding in the living room re-done. Here, the old moulding is removed.
cross section
The best piece of the old moulding is saved to make a template. A cross section of the old moulding reveals that the moulding was run in place, and the Greek keys were stuck on later.
squared uper
rebuilding DC
The moulding is squared up first by cutting with a miter saw. I cut another piece of aluminum from my rebuilding DC sign.
You may have seen it before. I have been using this sign for eight years.
mold template
back up for template
A mold template is made by cutting and filing a little at a time. The mold template is screwed to a wood backup. The last two details are screwed on and bent back. These not only make the last step, but allow the mold template to slide easily.
cornice strip and sled
truing up screed
A wood strip is nailed to the wall for the template to slide on. The ceiling is checked wit a miter rod. The ceiling must be dead straight for the moulding to look right.
filling in

The moulding is filled with moulding plaster and lime and run with the mold template as the mortar starts to set.
running mold
mitering joints
After several passes, our moulding is shaping up. The joins are tooled in with a mitering rod.
casting filigree

I got this mold rubber from smooth-on. It is made for casting details
on the wall. After four coats, I had a decent copy.
I made a plaster backup,and a box for casting. I poured the
Greek keys in sections about a foot long with moulding plaster
trimming filigree
scoring back
The casts are trimmed to fit using a knife. The back of the cast is scored to provide a good bond.
The casts are the stuck on using moulding plaster and lime.
All there is left now is to fill the joints.
finished moulding