Happy 2012, y’all! I hope everyone had fabulous holidays and fun times ringing in the New Year. Now it’s time to get back into the swing of things, so let’s do it.

You may have noticed that I haven’t posted in ages (it’s been about a month, I think?). I’ll confess – I’ve been in a rut. My muse seems to have been on winter break. Well then, Here’s my resolution. January brings with it optimism and the notion of a clean start, so I vow to give the blog more love in 2012 – even if that means having to get up earlier to write posts. (…okay, that’s unlikely to happen. Fine, I’ll just stay up later. Problem solved.)

I’m starting this new year off with a new project – a glass and porcelain memorial tile for a friend. MG readers may remember a similar tile I did last year. Both tiles will be installed on a tombstone and thus permanently exposed to the elements. All materials, adhesives, and construction need to withstand the freeze-thaw cycle of Michigan’s climate. But this new tile presents some unique challenges that are keeping me on my toes, all pretty much stemming from the fact that it includes a real pearl.

I’ve never mosaicked with pearls before, and certainly not in any pieces destined for permanent lives outdoors. My three primary concerns: How to embed the pearl absolutely securely in the adhesive, without fear that it will be pried out or pop out over time? Will the icky chemicals and colorant in the epoxy grout damage the surface of the pearl during the grouting process? Pearls are pretty soft – will the pearl be damaged by exposure or erode over time?

To address the first issue, I ultimately decided to use a single pearl earring so I could embed the post in the mortar adhesive underneath the surrounding mosaic pieces for added stability. Another option that had crossed my mind: drilling into the pearl and then drilling through the tile, back-mounting it through the tile before assembling the mosaic around it. This seemed more complicated than necessary, but who’s to say which is the best way?

I’ll have to save concerns #2 & #3 (how to protect the pearl during grouting & from erosion over time) for Part 2 of this post series because, er… I haven’t quite settled on the specifics yet. But without further ado, here’s how I’ve completed this project so far:

1.) I measured the correct tile size and sketched the design onto a rigid cardboard surface, then wrapped the cardboard in clear contact paper, sticky side up.

2.) I cut the mosaic pieces from smalti using wheel cutters and built the mosaic onto the sticky surface of the contact paper.

3.) Before adhering the mosaic to the tile, I cleaned the tile (high-fired porcelain) in a dilution of muriatic acid.

4.) With the entire mosaic complete & the tile clean, I then mixed a small batch of thinset mortar adhesive for exterior use (I used Laticrete MegaBond with MegaBond Additive) and transferred the mosaic piece by piece from the contact paper to the tile, making sure to stay within the fresh working time of my mortar.

I had to make a few adjustments and recuts here & there, but for the most part the mosaic transferred well.

 Now I just need to let the mortar set and then I’ll be ready to grout. Will the pearl survive? What solution will present itself for protecting this delicate treasure of the sea from the cruel fists of winter and time? Such drama! Check back soon and find out.