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Tom Landon writes:
David R ~
Here is a low tech approach to your dilemma of duplicating
the missing panel. I took some photos of a similar repair
as we did it last month. The piece we did was smaller than
yours but I think this method should work for you as well.
Our mold making material was none other than
the epoxy stick that looks like a tootsie roll.
Many suppliers market the stuff, ours come from PC Coatings.
I think we used a couple of rolls @ $4.95 each.
Here are some photos showing the steps:
This indicates the missing area.
Mohawk Slideez (drawer lube) was used as a release agent
on the wood and the epoxy putty was pressed into place in
another area of the table where carving matched the area
that was missing then allowed to cure.
When pulled from the table edge the mold (top) was coated with Slideez.
Again, epoxy putty was mixed but this time it was pressed into the mold.
When cured, the new piece was removed from the mold (bottom).
The duplicated piece was lined-up, doweled, and glued into place and
holes were drilled through where the original carving was pierced through.
Here we're using a scroll saw blade to open up the holes
that were previously drilled. The blade made the drilled holes
look carved and no longer round in shape.
The casting was then stained to match the rest of the table.
The completed repair.
Total time to complete the repair was aprox. 3 hr.