Building Replacement Markers
1 Build a frame to hold the concrete in place until it cures. The form is made from 1"x 6" boards with plywood. Here is a description of the forms.
2 - 1x6x24" vertical sides
2 - 1x6x18" horizontal sides
Place one of each lengths into a tee shape, square them and screw them together. The top of the tee is your base so turn it upside down and the top becomes the side of your floor of the form. Cut a piece of plywood 18x18" to tie the two tees together and your floor is finished. Use screws to tie the tees to the plywood floor. Don't use nails anywhere; you don't want to hammer anything to get the forms off when the concrete dries. Cut 2 pieces of plywood approximately 14"x18" for the front and back. this front is where you will stick your letters on. When ready screw them in place [after letters are glued on]. 4 more pieces of plywood finish the form. They will be about 14"x6" to be horizontal and vertical end caps for the ends of the tees. All these are screwed into place. Leave the top open to pour in the concrete mix.
2 Cut out letters and numbers.
3 Glue the numbers inside the form you built in 1.above. There is a gotcha here! Glue the letters as if you were looking thru the wood to the letters. In other words the glue goes on the front of the letters not on the back as you would normally glue on stuff. Use the kind of glue that you set floor tiles with for two reasons a] it holds firmly until the concrete is poured b] it releases as soon as the concrete is cured but the impressions are lasting and as deep as the thickness that you made the letters. Imagine for a minute that the front of the form is glass and you are looking thru the glass to the interior of the form what you see is the writing you want to put on the marker just as you want to read it. Keep this thought in mind as you are gluing the letters in place.
4 When you have the form made and letters glued into place [glue has set] take a paint brush and spread oil, about a 30 weight heavy oil all over the letters and front side inside of the form so the concrete will not stick to the letters or to the front side of the form. If desired oil the whole inside for ease of operations.
5 Mix the concrete a little wetter than you would normally pour a sidewalk then pour it and let the concrete cure for several days probably 3 or more days is best. then remove the form and voila you have a tombstone with proper looking message that will last until some idiot decides to break it with a sledge hammer or worse.
6 I put a little reinforcement in my concrete to make it more durable. i.e. two little pieces of pipe running top to bottom inside the form. Or you can use a little grill work e.g. wire mesh or any old steel or iron rods lying around will strengthen the concrete.
7 There are many variations you can choose. I cut out the letters on my scroll saw but a band saw will work. Probably you can talk a local friendly woodworker into making the letters free for you. They should be made from 3/8" thick plywood. Letters any thicker would probably be too hard to remove from your forms without damaging the image you want to leave impressed in the concrete.
This design is based upon 2 bags of concrete mix at approximately $2.00 each at 40 pounds each so the final marker weighs about 90 pounds.