@angellonewolf mentioned resin. Now I know this stuff really does stick like the proverbial. It's what I used to stick the M5 studs in that hold the mesh on. I wonder if big blobs of this would better hold the actual flints? Would have be very organised and have a plan so it's not going off in the nozzle.
Hmm...on the test flint the Sticks Like Sh!t seemed to have fully dried after 24hrs. The (white) Ever Build Multi Stick was still a bit sticky underneath. On balance I'd say the Sticks Like Sh!t was adhered better. Still managed to pull it off.
Second panel flints in their sand box for reference.
I figured the flints being spotlessly clean might help. To think SWMBO moans I never load the dishwasher!
Looks like I got away with the dishwasher trick. Had it done, unloaded and restacked with dishes without her twigging.
They came out rather impressively hot and in fact held their heat for a long time...(future heat store project?)
The next, new, rough plan goes like this then:
I cut a board the size of the recess. Found another bit of mesh. I organised the flints how you'll see them face on like the reference photo. I then mirrored the photo. Copying that, or at least the outline, I've laid the flints face down on the board then tried to rearrange with reasonable gaps. The mesh gets laid on top and the mesh cut out where the high points are. Shouldn't matter if it doesn't sit quite flat. I'll clamp the mesh down onto the flints then blob Fischer or similar resin on each flint to hold it to the mesh... hopefully!
Generally seems to have dried ok. If the resin sticks to the flints like it does my hands I'll be well happy.
The odd lighter coloured blob (though not all of them) is still wet, uncured DeWalt resin from the tail end of the tube, when it was just resin coming out with no hardener. Maybe as it was a bit out of date? I'll live with it as the tube was a freebie! Resin is horrible to use from a normal gun imho. Much prefer the Fischer, space shuttle esque resin tubes. My daughter couldn't squeeze the DeWalt stuff in the standard gun. With the Fischer gun it's a doddle.
The "towers" are a concern as in where the distance from mesh to flint is such I've had to build up the resin in height to bridge the gap.
Now to try and "hang" one without everything falling off!
Must get laddo to print up some pads for the clamps so they sit over the "+" of the mesh and don't slip off.
I'm waiting for the new plan where you cement them in, in the traditional manner and see if any fall off.
All these alternative methods have just as much likely hood of failing long term in my opinion.
I’ve built several extensions and walls using flint . With the extensions we used pre made units .
They were fast concrete blocks 440x 215 to match standard bonding . The company wet casts into formers , whilst still wet they set the flints into the mix . Let cure then remove . We never had any fall out even after handling and cutting the blocks to suit . The mix was wet/ dense and the flints roundish .
The guy said he buys the flint of the local farmers who stone rake their fields . He is based in Dorset , not far from Dorchester .
After building , you then point the whole building in , so it unified it . Unless you built it , you wouldn’t know
Well...chucked in some M5 stainless studs with more of the crappy (but free) DeWalt resin. Ran a full nut down then another st/st washer.
Then hinged the board with the stones on into position and hooked the mesh over. None fell off!
I thought I'd worked out the studs so they would project in the gaps. Nope, got 3 out of the 6 wrong! Had to bend the other 3 to miss the flints. Once on then another penny washer and full nut. The fun is getting your finger in and winding the back nut further in to push the flints further back.
I don't think I'm happy with some of the spacings. Might mess around with the bottom left.