Foster used architectural elevations from the Manor itself, and programmed them into the router. Then he etched them onto Formica, the windows, brick texture, everything. Meanwhile I had a team of RPFers modeling things like balustrades, columns and vases. We then assembled all the pieces into an exact scale model of the Manor. The whole model came apart into 30 pieces, and we made rubber molds of each part, then cast each part in resin. I learned a technique called "cold metal casting" where we mixed copper and brass flakes into the resin. We then assembled the resin pieces and polished them up to a high sheen. It looked exactly like a bronze casting of Saint Hill Manor. The model was then mounted on a shiny black base with a plaque. It had taken us seven weeks – including learning how to do it. And we had done it for about $500. I preserved all of the molds and documented exactly how to do it for future trophies.
Our finished project - the Saint Hill Size Trophy
In March I was promoted to Director of Art and Signs, where I designed and manufactured all of the signage for the new Applied Scholastics center in Missouri – on time and under budget.
In April, I was in my office when the door opened, and David Miscavige walked in, with Shelly and Lou. He was on an inspection of Big Blue.
"Jeff, what are you doing here?" he asked.
I tried to explain my promotion to Director of Art and Signs, but it turned out he had no idea I was even in the Complex. I don’t know where he thought I was – or if he even gave it any thought.
Extract from http://counterfeitdreams.blogspot.com/