My First Fumble
Transforming challenges into triumphs is at the heart of every great venture. This is the story of an ambitious project that not only tested my limits but also paved the way for Cheyenne Garden Fixtures.
The First Giant Leap
In 2022, I faced one of my most significant challenges yet. A good friend and Wyoming strongman athlete ordered a custom 22” Atlas Stone, aiming for a hefty 440 pounds. Up until that point, my experience was rooted in crafting considerably smaller stones. The scale of this task was daunting, but the journey it took me on was invaluable.
Facing the Unexpected
1" Is a Big Difference
Shot of the First Stone… Obviously, mistakes were made.
In the world of sphere-making, every inch matters more than one might think. For context, a 10” sphere weighs about 35lbs, whereas a 12” sphere jumps to 65 lbs. That's a 20% increase in diameter resulting in nearly double the weight. This scale-up is even more dramatic with larger orbs—a 21” diameter sphere weighs around 365 pounds, but adding just one more inch increases the weight to approximately 440 pounds. When I began pouring the 22” stone, I quickly encountered unforeseen challenges.
Cement Was Too Dry
My initial approach to mixing cement hadn’t been precise. "Eyeballing" the mix had worked for smaller projects, but it led to a too-dry mixture for something of this magnitude. This oversight resulted in visible layering within the stone, far from the smooth, uniform quality I aimed for.
Porosity Needs to Be Addressed
Another issue was the natural air pockets forming in the cement, which created large pores and a rough finish. This was not just a cosmetic issue; it posed a real risk to athletes, with sharp edges that could potentially injure them upon lifting the stone. Addressing this porosity became a priority to ensure the safety and functionality of the stones.
Crafting Solutions
1. Upgrading the Mixing Process: The first hurdle was the quick-setting cement that led to unwanted layering. To combat this, I significantly upgraded my equipment, allowing me to mix larger volumes of cement simultaneously. This investment enabled me to pour the stone more swiftly and consistently, eliminating the issue of layers forming between batches. With this new setup, I could mix and pour 20 bags of cement in just a couple of hours, a game-changer in the creation process.
2. Refining the Cement Mix: Realizing the consistency of my cement mix was off, I reached out to local friends in Cheyenne working in the cement industry to dive deep into the science of cement mixtures. After a series of consultations and experiments, we identified the ideal mix ratio that I still use today. More importantly, I systemized the mixing process to ensure this perfect ratio was replicated precisely with every stone, ensuring uniform quality and durability.
3. Tackling Porosity: The porosity of the stones was a critical issue, not just aesthetically but for the safety of the athletes using them. I engaged with my local network in Cheyenne, pooling knowledge and experimenting with different methods to address this. The solution varied by the size of the stone and the desired finish, leading to a tailored approach for managing porosity. These collaborative efforts resulted in multiple effective techniques to minimize porosity and ensure a smooth, safe surface on every stone.
These three solutions not only resolved the specific issues at hand but also set new standards for quality and safety in my creations. They underscored the value of community, expertise, and the willingness to innovate, principles that have become the foundation of everything we do at Cheyenne Garden Fixtures.
A Foundation of Learning
Eventually, we shipped out a great stone!
The experience of creating that 22” stone was humbling and enlightening. It was a stark reminder that every challenge is an opportunity to learn and grow. The lessons learned from this venture were instrumental in establishing the standards and practices for Cheyenne Garden Fixtures. This process didn’t just result in a single stone; it laid the groundwork for the creation of beautiful garden spheres, each a testament to the journey from challenge to mastery.
My friend still trains with the stone I crafted for him, a symbol of resilience, learning, and the relentless pursuit of improvement. This story, the very essence of Cheyenne Garden Fixtures, reflects our commitment to overcoming obstacles and creating something truly remarkable.