Start by measuring the space where your numbers will hang. You'll want to select a ratio that's big enough to be visible from the street, but not so big that it's sticky. You can get creative here, but if you're nervous, a rectangle is an easy way to work. Cut a piece of 1/8” plywood to the dimension selected for the baseboard. Head over to your computer and print out some numbers at your desired size and paste them together to make a template to fit your baseboard.
Framing on the back of the base plate allows the mounting hardware to remain hidden and prevent it from interfering with the tile that will be attached to the opposite side. Cut a 1x3 for each side that frames the inside area of the base plate.
Now it will be much easier to install the screw eyes in the frame than once the tiles and plates are attached to the baseboard. Even over the two longest frame rails, draw a line about 6"-8" from the top ends and install a screw eye into each.
With both screw eyes facing up, apply a generous amount of wood glue to each rail and clamp in place. Make sure that all four sides are in even contact with the baseboard and that they are securely fastened until the glue has been allowed to dry for the recommended amount of time.
Place the piece of carbon transfer paper on the plywood side of your baseboard and use painter's tape to secure it snugly. Then place your artwork on the carbon paper and pin it in place as well. Try to keep everything nice and flat and keep it from moving around. Once everything is ready, use a pencil to draw over your design by hand. The pressure of your pencil causes the charcoal to release from the transfer paper, leaving what you have drawn on the wood below. Then use a permanent marker to outline everything so you can see it clearly as you lay your tile.
You can add almost anything on your mosaic; seashells, pebbles, glass, ceramics, broken dishes, or just any regular tile scraps you have lying around. In the event that you need to break things into smaller pieces, you'll want to use some security. Sturdy goggles and gloves are an absolute must. Use a small piece of wood to absorb some of the blow from your hammer, and place a towel over anything you plan to break to prevent shrapnel from flying. Start with a light touch and increase your hammer blows until your object breaks. You want it to break easily, not explode into a million pieces.
The goal is to make the numbers as visible as possible. Use the most prominent colors or materials for your numbers to make them stand out. Then use a heavy-duty construction adhesive to glue the mosaic pieces to the plywood baseboard. Firmly press all of your pieces together and allow them to dry for the recommended amount of time before continuing to the next step.
Now that your numbers are in place, you can begin to fill in the background space with your less prominent colored materials. Adhere your bottom pieces in the same way, making sure to keep the tiles from hanging off the edge of your baseboard.
Once all of the adhesive has cured for the proper amount of time, you can apply the grout to fill in all the gaps between your tiles. Grouting doesn't need much in the way of tools or effort. You need a grout trowel, a sponge, a bucket, and a bag of unsanded grout. Start with a few handfuls of grout and slowly mix in water until grout is smooth and the consistency of peanut butter. It should be a bit spreadable and a bit sticky, you definitely don't want it to be too loose.
Once your grout has reached the correct consistency, it's time to spread it. Place a thick mound of grout in the center of your masterpiece and use the edge of the trowel to work it into the cracks. You want a nice smooth coat, but it's more important to make sure all the gaps are filled and the outer edges are nice and clean. You can get close to perfect in the next step, but you'll have to wait about an hour before doing it.
After an hour or so, take a slightly dampened sponge and start wiping the grout off the tiles while giving the entire piece a soft cloth down. Clean the sponge often and make sure to squeeze out about 95% of the water before putting it back on your piece. Your grout needs to set, but it's not fully cured, so you need to clean up your work, but it's not perfect.
After that initial sponge bath, your masterpiece needs to sit for about six hours to harden. After that time has elapsed, you'll want to give her a second sponge exactly the same as before. You will now notice that your artwork is starting to shine. Once you're done, let your project rest for 24 hours so the grout can fully cure. When you return tomorrow, you will notice that a fine mist has developed on your tiles. Don't worry, this is the last step. Take a clean, damp cloth and give your work a final polish. This should lift the film and your grout is officially finished.
Tiles tend to leave pretty rough edges, so framing your project really gets it going. Cut some more 1x3's and finish them however you like. We use mahogany chunks with a nice polyurethane coating. Secure the edges of your frame with some construction adhesive and a few small nails on each side and in the corners.
Your mosaic will probably be quite heavy at this point. It is important to use a wire to hang a strong picture in the eyes from the screws on the back. Make sure to add a few twists to keep it in place and cut off the excess with pliers.
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