How to make a Texas Popout Address Stone

The process we use to make our Texas Popouts


Getting the Material

We use several material yards in the San Antonio area. We locate limestone building blocks that are at least three inches thick, 18 inches tall and 20 inches wide. This is not a common size. They are heavy. One week we found four stones, and the total weight for those four stones was 465 pounds, so each stone was well over 100 pounds in weight.    
Rattlesnake building blocks
We then deliver them to our "waterjet guy".

Water jet Cutting

Waterjet Cutters are amazing machines. They can cut 4 inch aluminum plate, 2 inch stainless steel, or several layers of other materials simultaniously. They aren't really made for "one at a time" jobs, they are made for mass producing items.
The Waterjet forces water mixed with garnet through a nozzle at 60,000 psi. It sounds like a jet engine. You have to wear ear protection devices.

aligning north
verifying
move home point
check north again
last check
we "punch in"
east side of panhandle

spraying 15 feet!
showers continue.
water shield!
about to return to high
johnny checks progress
el paso
panhandle bound

panhandle
turn corner
near amarillo
inches to go
one inch
back to start
all done
we now have the complete outline,
and tap gently with a ball peen hammer.
along the red river, west of the panhandle, then east of beaumont....
completed cut
first tap
second tap
third tap
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