You will need a chisel as well as an electric grinder with a diamond cutting blade to cut the stone. [2] X Expert Source Gerber Ortiz-VegaMasonry Specialist Expert Interview. 10 March 2020. If your project is small, it may be less expensive to rent the grinder. You’ll need a stone mason’s hammer (these are similar to small sledge hammers). You will also need safety gear. You’ll need protective goggles, a full face shield, and hearing protection. You can get hearing protection, which are ear muffs designed to block out loud sound from machinery, at most hardware stores.
Take your chisel and hold it in a vertical position on the stone, with the blade of the chisel on the line you wish to cut. Take your sledgehammer and hit firmly it on the end of the chisel to make three or four small marks, about an inch apart, running along your line on the stone. Then, fill in the spaces between these marks by once again tapping your chisel with the sledgehammer. Keep working the line until you have a groove the entire length of the face side. Use single, solid taps against the chisel with the sledgehammer, working back and forth up the line.
Use your grinder to cut a straight line across one side of the stone. Cut over the line a few times, until you have a small indent. Go slowly to make sure the line is cut evenly across the stone. Turn the stone over and repeat this process on the next side of the stone. Then, turn the stone over again. You should repeat this process on all of the sides of the stone other than the face until you have a good groove on each side of the stone.
Start with the face side, and give 3-4 good blows with the hammer along the groove in the face. Rotate to the next face, and repeat. Continue this process (it may take a while) until the stone breaks.
You will need a chisel set containing the following types of chisels: a large, heavy chisel, a point chisel, a claw chisel, a flat chisel, and a file. Chisel sets can be purchased online and at most hardware stores, but can get pricey. A set may cost up to $100. You will need dust masks to wear during the shaping process, as well as safety goggles. Leather gloves are a good idea as your hands may get sore while carving.
Scrape your chisel along the stone, carving it into the rough shape you want. Carve along the edges of the drawings you’ve made. Make sure to wear your safety goggles, as bits of stone may fly off during this process. Do not break off big chunks of the stone. Instead, take out small bits of stone one at a time. Try to make a series of groves in the stone with tiny bits of stone wedged inside. You’ll remove these lines later, with other tools. A large chisel can be rough on stone, and is not delicate enough to remove such lines.
You should hold the claw chisel at about a 45-degree angle. However, the angle varies slightly depending on the roughness of the stone. For particularly rough stones, you may have to go for a steeper angle as you scrape the chisel along the stone. Once again, go slowly. Remember, it’ll be awhile before your stone truly begins to take shape. Make a series of small lines in the stones running along the exterior of the shape you’re carving. Make lines about 1 to 1 and a half inches apart. Then, make a crosshatch pattern by drawing lines the other way. This levels the stone, creating small bumps that can be removed with a claw chisel. Your stone should look something like the shape you desired, except the exterior of your shape will be bumpy and uneven.
Remove any jewelry before you begin working. If you have long hair, pull it back into a ponytail. Avoid wearing shorts, as pant legs can protect you from bits of stone that may fly away from the main piece while you’re cutting.
Commercial use implies there will be a lot of traffic on your stone. For example, stone used on a walkway or on the floor of a shopping mall would be commercial use. You should go for a heavier, sturdier type of stone. Limestone, a common stone used for DIY projects, should be avoided. Domestic use is stone that would be used privately in your home. A stone counter would be domestic use, for example. You can use softer, cheaper stone for a domestic project. Stone types like granite or other natural stones would work well.
In general, the thicker the stone is, the more expensive it will be. However, thicker stone is also more durable. For a flagstone patio with a crushed stone base, go with stone that’s at least 1. 5 inches (3. 8 cm) thick. For a patio with a concrete foundation, go with stone that’s 1 inch (2. 5 cm) thick. [16] X Expert Source Gerber Ortiz-VegaMasonry Specialist Expert Interview. 10 March 2020.
