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Foam teal project

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Foam teal project
One of my favorite hunts of the year is in Louisiana where i have a lease. It is a teal grey duck and pintail shoot over fifty or so wood blocks. i hunt from pit blinds in the marsh but the ducks feel the pressure and retreat to spots that i need to walk in quite a distance.
I have been noodling on a big rig of teal that would be light enough to drag around from place to place. So fast forward to my project.
I used 2 inch pink foam
3D printed heads
construction adhesive
thin set mortar
titebond



DHBP Member since May 1999
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DHBP Member since May 1999
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DHBP Member since May 1999
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DHBP Member since May 1999
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Interesting with the 3D printed heads..
What material did you use? My son does a lot of 3D printing, never crossed my mind...Thanks
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I got 75 or so out of a 4x8 sheet of foam. I used a simple pattern . Before shaping i cut a slot in the centerline bottom and glued a chunk of lead . The coating was a test of various materials . Corn cob , sawdust burlap . i decided on a mix of thin set titebond and water with sawdust 2 coats . Head in pic is prototype made from 3/4 pine but i'm having it duplicated on a 3d printer. No detail on head or bill. more to come .
DHBP Member since May 1999
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You and I are in the same boat. We have sons that are way more technical than their fathers. My son is working on mine and we are down to the final prototype before production. He is using ABS and can make the heads thin or thick or light or heavy but it comes down to how strong do you need it to be . He thinks about 35 cents a head
DHBP Member since May 1999
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Awesome project! I am in on a camp in S. Louisiana. September teal season is my favorite time of the year, next to big duck season of course!

How long does it take to print one head?

What are the dimensions of your teal bodies?
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Paul, My son ran three prototypes making changes for shape and density. The last one included a threaded hole for a 1/4 screw eye. I don't know yet how long each copy will take but he tells me that at that point it's just hitting the button and having the machine loaded with the abs spool .

The simple body is 10 x 5x 2. It's a flattie but i bring the neck area down by a half inch about an inch back from the front to create a bit of a shoulder.
The coating is drying hard on the first batch . I visit some of the foam sculpture and modeling sites to get some tips but it's pretty much a restle coat tweaked.
I plan on texas rigging them and am working on an anchor attachment options.
DHBP Member since May 1999
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DHBP Member since May 1999
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DHBP Member since May 1999
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Love this kind of project, I?m enjoying seeing your process!
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That's awesome! I look forward to seeing the finished decoy!
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I've got 50 bodies in various stages of competition. I can whip out the bodies in 5 minutes and when i get a dozen or so I mix up the glue water and thin set. I apply with a cheap brush to the raw foam and sprinkle with sawdust. The first batch of coating came out a little coarse so I swiped a noodle strainer from the kitchen and dusted the wet birds by shaking it over the top. My experience over the years has been they can be abrasive in the boat or bag so trying to mitigate the chafing.
DHBP Member since May 1999
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very cool project, you're really cranking them out.
only 6 months until teal season!


Carl
Mobile, AL
DHBP Member since 1998

"Life is too short to drink bad beer."
Disclaimer: This post and/or report is not a substantiation of or reflection on the true accuracy of the present surveying methods. It is only a report on or comment concerning local observation and/or results. Your results and observation may vary based on your location, local water conditions, food supply, weather conditions and migratory patterns "
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Waiting on the 4th revision of the head. I will see it today. Its taking a bit of time because my son is a couple hours away so its a long time between revisions. And hes doing me a favor so I cant hound him like I used to when he was a teenager!
In the meantime most of the 75 bodies are dry enough for the primer paint coat of rustoleum. So far they are drying and curing very hard.
DHBP Member since May 1999
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Bodies must go fasr with the pnumatic sander.
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I tried the sand rite on the foam but it produced to much fine dust. Over the last 40 years I have eaten alot of cedar and pine dust and its probably not so good for me, but I drew the line with the foam. All the bodies were done with a rasp and a course sanding belt wrapped around a 2x4 scrap. Still only took 5 min. Years ago when I worked in alot of black cork using the sanding drum, I would be blowing my nose black for a week. (sorry about the mental pic).
Winter is still hanging on in Chicago so I cant rely on the sun to bake these hard just yet, but I do have most of them primed.
DHBP Member since May 1999
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I too am more careful with dust after my non-smoking Father died of lung cancer. I can't work in a mask, so bought a large down draft table that I ducted outdoors. I can even spray paint over it and barely smell anything upstairs in the house.

Dave Diefenderfer
Manassas, VA

"Once you set out to build a boat, throw away your square. And if you work on her after she's launched, throw away your level." author unknown

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I even wore a mask when cutting them out on the bandsaw. Starting the Save What I Have Left tour.
DHBP Member since May 1999
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This is an awesome project! thanks for sharing.
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First batch new count 87. Just obtained another foam sheet. wash . rinse. repeat
DHBP Member since May 1999
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Nic project. My question, and not trying to be a jerk - how far do you have to carry all these decoys? On opening weekend, we walk in about 1 mile. Three of us hunt one spot and each can only carry about 6 plastic decoys in and out. More than that, and it is too much. I even went out and bought foam shell floaters and blow up teal dekes as these are much easier to carry in and out.

We have learned, and as you probably know, going in is easier as going out we have 18 ducks to haul as well.

Mark
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After posting the pic of myself in that marsh, I could see somebody saying "how's that old timer going to carry all those blocks." Since this is a duck boat site ,I have many craft at my disposal. Water level is about a foot deep and a hard bottom. The Lund Ricer or my 18 ft pirogue is going to haul the gear.
I was thinking of texas rigging using 3 ft lines and 4 ounce weights.
DHBP Member since May 1999
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Still waiting on the 3d heads so i cut a couple out of wood to play with paint schemes. First i used nylon cable clamps with a plastic washer with a deck screw coming from the bottom into the head bed in gorilla glue. Black rustoleum flat base coat. Alkyd paint finish coat and tube oil. Drying in front of shop heater. Conceptual paint pattern. probably use less detail based on the coarse texture of the surface.
DHBP Member since May 1999
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the makings of a 167 bird teal rig
DHBP Member since May 1999
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Bob,
I have used those cable clamps quite a bit at work. The white ones became brittle in just a couple years. We use the black ones now that are suppose to be more durable but I have not had them in use long enough to know yet. Hope that can save you some free floating blocks down the road.

"UNLESS someone like you cares a whole awful lot, nothing is going to get better. It's not."

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Thanks Brandon, Im trying to come up with anchor line attachment options. Thanks for the tip, anybody have an idea for a anchor tie off point? I am trying to keep the bottom of the decoy as smooth as possible to avoid chafing the other decoys in transport.
DHBP Member since May 1999
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Bob,
We have used these for the last 10 years at work and they are out in the sun. They hold up. Maybe you could modify them?

https://smile.amazon.com/...le?ie=UTF8&psc=1

"UNLESS someone like you cares a whole awful lot, nothing is going to get better. It's not."

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How about a heavy duty nylon cable clamp attached to the head anchor screw?

https://www.homedepot.com/p/NSi-Industries-Heavy-Duty-Nylon-Cable-Clamps-0-375-in-Black-100-Pack-NCH-375-0/307357591?source=shoppingads&locale=en-US


Carl
Mobile, AL
DHBP Member since 1998

"Life is too short to drink bad beer."
Disclaimer: This post and/or report is not a substantiation of or reflection on the true accuracy of the present surveying methods. It is only a report on or comment concerning local observation and/or results. Your results and observation may vary based on your location, local water conditions, food supply, weather conditions and migratory patterns "
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Carl, thats kind of what i got, but looking at grainger they have a heavy duty model.
Brandon, those would work with a longer screw.
DHBP Member since May 1999
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Bob~


I'm really enjoying this thread - your R&D staff are going full bore. Can't wait to see your printed heads.


I may have missed this detail: All GWTs - or some Blue-wings, too?


All the best,


SJS


Steven Jay Sanford
Pencil Brook Farm
South Cambridge, NY
http://www.stevenjaysanford.com


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Steve, I have the Top Men of DHBP working on this project now TOP MEN!!! I was down this road last summer when i repainted the big mallard rig and found that parts of it are like working on an assembly line and never seeing the finish line. I mixed it up yesterday and painted a couple prototypes. The hen is too mallard hen like in base color. i need to grey/brown the base coat a bit. The rough texture will limit detail on both.
I think the body pattern will work for both gwt and bwt and one of my head profiles will be interchangeable. I know the live birds are very different but i don't think it will matter much at 20 yards.

DHBP Member since May 1999
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Great work, you are a one man
Factory! I love it.





Oxford, CT
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Bob, YOU understand the twenty yard philosophy. This, and sweat, bandages and dust now entitle you to be a decoy maker!
george@runamuckdecoys.com
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As normal I'm a day late, but Stainless cable clamps are available. Additionally did I miss the actual coating formula you're using? Glue, water and thin set, but roughly what proportion of titebond to water? I.e. how watery before adding the thin set? Definitely enjoying your project.

Scott
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Thanks for the encouragement fellas. Getting alot done in this cold wet spring. I painted up a few more samples trying a new paint scheme. The printed heads are not finished yet so Im waiting for that step. Scott , I mixed the thinset with water according to the bag instruction then in another container mixed up some titebond 2 and a bit of water then poured it into a cottage cheese container and mixed it really well. It came out like a thin milkshake . Thanks for the tip on the clips. They are in the running but I ordered the ones Brandon mentioned yesterday. And you nailed it, A day late...
DHBP Member since May 1999
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Bob, if you need color schematic for the teal, drop me a note
gwdecoys@verizon.net
Will send you printable info.
george@runamuckdecoys.com
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My son sent the mock up and modeling of the heads to me today. The material is a low cost plastic he uses for modeling. The final I believe fill be done in ABS plastic.
DHBP Member since May 1999
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the top middle and far right shows the neck build up with the threaded hole for a 1/4 screw. the piece under the bill is just for support during the process and snaps off real easy. the heads in yellow are a mock up of how many he can fit on his table at one time.
Babies must have been switched in the maternity ward thats the only answer i have.
DHBP Member since May 1999
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bob welsh wrote:
Steve, I have the Top Men of DHBP working on this project now TOP MEN!!!


Raiders or the Lost Ark reference???

Great looking project you've got going there!

.........................................
Recovering Engineer, Standup Philosopher, Aspiring Pirate, Cooking Enthusiast
"Life is a garden.... Dig It!"
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you are correct sir
DHBP Member since May 1999
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Really cool stuff!!


Carl
Mobile, AL
DHBP Member since 1998

"Life is too short to drink bad beer."
Disclaimer: This post and/or report is not a substantiation of or reflection on the true accuracy of the present surveying methods. It is only a report on or comment concerning local observation and/or results. Your results and observation may vary based on your location, local water conditions, food supply, weather conditions and migratory patterns "
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Bob, not being critical, really asking because I have seriously thought about doing this! Did your son use a 3D scanner? Curious why you are going with a flat head? Because he scanned what you carved from narrow stock?

Dave Diefenderfer
Manassas, VA

"Once you set out to build a boat, throw away your square. And if you work on her after she's launched, throw away your level." author unknown

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I provided him with two models. One a flat stock 3/4 board with the corners knocked off and a full carved almost decorative style with cheeks and bill detail. The first ones were the flattie style and will work but not all that fancy. He does have a scanner and will incorporate that in the second batch on the detailed head. But yes your critique is valid . Once you have the head modeled any extra detail is no big deal. I was going to go the mold route but if i can get what i want out of the 3 d process it's way less cost and effort for 150 heads. By the way your recent offering in this months workbench thread is very nice. This project was inspired by your post on the INVADM decoys.
DHBP Member since May 1999
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Bob,

Thanks for sharing the recipe! I've still got dozens of cast EPS decoys to do something with.

Scott
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Bob~


Interesting!


I, too, leave the material beneath the bill when sawing out wooden heads. I saw it 95% - but leave a hinge so it's there when I'm sawing the plan view. Then I just snap if off when the time comes.





All the best,


SJS

Steven Jay Sanford
Pencil Brook Farm
South Cambridge, NY
http://www.stevenjaysanford.com


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got the new head scanned and it shows all the detail i want waiting for production to start. used a scanning app on phone and produced all the detail
DHBP Member since May 1999
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Put down a base coat on 40 hens. Got the color down thanks to George W for the detailed instructions. I did a test with tube oils and found the right shade and color matched in the BM super spec DTM alkyd that i always use. It's real hard drying stuff . It will dry with a low luster sheen which i wash over with a thin raw umber /japan dryer mix.
The heads are printing and came out better than expected. I have to pick them up this week so stay tuned.

DHBP Member since May 1999
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43 drake's ready to rig.Waiting on more heads. I need about 125 teal heads to go. I came back from MN for 10 days to work on decoys plant millett and upgrade the fleet.
Happy with the drakes although I added a little white on the head separating the green and brown and it's barely there in the live bird but chalk it up to artistic interpretation.

DHBP Member since May 1999
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How are the heads attached?
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Those are so sweet. Very nice.
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I attached the heads with a 3 inch deck screw going through a cable clamp and a 1 1/2 stainless washer. Glued the heads with construction adhesive. The heads have a built up inner post that took the screw well.
DHBP Member since May 1999
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Damn impressive!
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Very nice Rig. Should bring in some birds hopefully
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Those really look good Bob. What do you think of the Water Walker up against fence? Worth the money?

Take care,

Ed L.
East Moline,
Illinois
_________________________________________
If I'd had asked what they wanted they would have said faster horses" - Henry Ford

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Bob

Those are exquisite.

Eric
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Good morning, Bob~


My jaw always drops when I see your Magnum Opus. Fabulous rig!


And - yes - you did well with those Lines of Demarcation on those drakes.



This pair are E Allens:








All the best,


SJS


Steven Jay Sanford
Pencil Brook Farm
South Cambridge, NY
http://www.stevenjaysanford.com


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thanks for the kind words to all and especially to all that have chimed in with suggestions and tips. To reference one of my earlier posts in this thread, our Top Men have been a good resource to me in this project. I have taken a couple of weeks off and have been at the cabin up north in MN. I've been looking after my flowers and working on the cabin because there is always something to do here. The walleye bite is off now so heading home tomorrow to pick up where I left off. 3d printed heads are ready to turn into hens this time. One last sauna and back to Chicago (ugh).
DHBP Member since May 1999
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DHBP Member since May 1999
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Put some feather detail on the backs just because. I made some basic stencils and then went back with a fine brush and painted the centers and cleaned them up a bit. It's easier to paint the feathers this way without the heads on.
DHBP Member since May 1999
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DHBP Member since May 1999
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That is 100 GWT hens painted and ready for texas rigging. The three that i pulled out were from a painting session that was super simple but now that i look at them I should have just gone that way on all the backs. The other ones have the stenciled back feathers. I think i should have done them all like these three. There are 50 tick marks in each head so 5000 in all done over 2 days. The drakes are done except for 20 that I am short heads. Next week should fix that.
DHBP Member since May 1999
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DHBP Member since May 1999
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I texas rigged the drakes at the club over the weekend while I had down time watching TV in the evening after working in the marsh.
I bought all the rigging supplies from SNL corp in FL and poured 4 ounce weight.
DHBP Member since May 1999
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DHBP Member since May 1999
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Finished these up with some random foam bodies i had laying around for a little color to the rig.
That's all Folks!!!
DHBP Member since May 1999
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They look Great!!
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Teal deployed with success
DHBP Member since May 1999
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update on the rig. I brought the entire 225 bird rig to SW Louisiana for a nice trip. I was interested in seeing how the rig would travel from Illinois to the gulf in the trailer. That restle coating can be pretty abrasive but not much i can do in practically I couldn't wrap each one in its own bag. I used the full body goose decoy bags and put 20 or so still attached to the texas rigs into each slot. When i arrived they were fine. In the morning I but the bags into two boats and we motored to our approximate destination. We took the decoys out of the bags and loaded them into jet sleds along with guns ,bags and marsh stools. Walked from the boat ditch about 250 yards in the marsh to a big open spot. Placed the teal in clusters or pods with a few danglers around the perimeter. I had a friend of mine send me some aerial pics of teal and that's what i was trying to replicate. The birds ate it up. We all had good shooting for a week.
DHBP Member since May 1999
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DHBP Member since May 1999
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DHBP Member since May 1999