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Working with Core Flute

What is Core Flute?

Core Flute is sheets of plastic that look like corrugated cardboard. They are weather proof and are easily cut and painted. Real estate signs are also made from core flute.

Santa stands 4 foot tall and is made from core-flute plastic.

His first year was 2006. People were invited by a sign to have their photo taken with him. 

This turned out to be very successful and most people stopped, hopped out of their cars and stayed a lot longer than normal.

This is how I made him.

First thing is finding a suitable graphic. Once found I put it into a graphics program and applied a grid to it.Then I divided the core-flute into 8 x 5 squares, the same as the template covering Santa. I drew the pattern by freehand onto the core-flute to match the template. I used a black marker pen to finalize the pattern once I was happy with the pencil draft. I did this so the pattern could be seen through the primer coat. I suppose another way to do it would be to prime the card first before applying the pattern.

Note: The smaller the squares the better the end result.

Then I primed him with a spray-on plastic primer. This way the paint would stick for years to come. Then I painted the colours including white as the core-flute was dirty. Then the outline. Santa took 3 coats of Red, 2 of the other colours.

Once dry, I coated him in 2 coats of Waterproof diamond finish this will help keep him clean and in good condition for years to come.

Finally I hot glued the tinsel around the edge, attached a supporting board to his back, and screwed him to the gate.

To help him shine I placed a spotlight above him.

Done.

santa  santa2

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