Wednesday, November 12, 2008


Ummmmm. . .Yeah. . . so, that didn't work the way we expected it to. Once we removed the brace between the legs, it promptly cracked open again. The only way to be 100% certain it was fixed, was to break the leg the rest of the way off and start fresh. No wonder the previous fix didn't hold! That leg alone was VERY heavy, at least 10 pounds!

A glimpse inside the hollow leg stump and into the body. You can see the thin layer of fiberglass sandwiched between the two (interior and exterior) coats of resin. They must brush the resin into an open mold, lay the fiberglass on top, put the mold halves together and slosh another coating of resin inside the whole thing. That's just my best guess. . .I'm sure it's a bit more complicated than that.

We opted to go for a giant version of how the leg on a small resin horse can be fixed. Since the leg was already hollow, we skipped the part where you carefully drill into each section. We also skipped the part that involves fitting a thin metal pin into the two halves and opted instead for pounding a 2 x 2 into one side with a mallet. After packing the area around the wood with epoxy putty and letting it set up for awhile,

we fitted the other end of the 2 x 2 into the body portion of the leg which had also been packed with a generous amount of putty. We were careful to extend a thin layer of putty over the edges of the leg so there would be a tight seal between the pieces that would be easy to smooth and finish for a "seamless" appearance.

Once the two pieces were firmly pressed together, the holes that had been drilled for the earlier failed attempt at a repair suddenly came in handy. We were able to tightly pack more putty into the holes with the pieces in place to ensure a solid bond between the wood and the inside of the leg. Once everything was in place, we stood him up and adjusted the leg so it lined up properly with the hoof flat on the floor and the body weight supported evenly. About 15 hours later it was solid as a rock, ready to be sanded smooth, and finished with a fresh coat of paint! Yay!

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