Our process started with rubbings made from some of the remaining original addresses. This genesis is our touchstone to producing truly heritage versions. From these rubbings, master numbers were made out of a stable wood composite. They were checked sanded and sealed. Once the masters were made we created molds using cast urethane. The molds are given several days to cure before they are separated from the masters.
Once the moulds were made the actual production starts. Production of the numbers begins with high quality plaster of paris and purified water. Plaster of Paris has about a five minute potlife which is usually a comfortable pace for the batch size that we pour. The numbers sit overnight and are taken out of their moulds the next day. It is requires skill and patience to extract the numbers from the moulds. We usually are doing well to get 50% of the fives that we pour into production. Threes can be a problem too. The numbers need to cure now and dry slowly for a week. The fully cured numbers have a special "sound" to them when you pick them up and run your finger over them. They are also very light. That is when they are ready for sanding. The numbers are sanded flat on the backside to remove the excessive slump and flash where they run over their moulds. I should point out that the numbers are cast face down (you pour the plaster into the back side). Carmen has developed the skills of a surgeon when handling these numbers and has the feel for when they are just right.