Restoration Commission: Saving a Ceramic Nativity Icon – Crack Consolidation

Some restoration projects are straightforward, while others truly put your skills, patience, and creativity to the test. This restoration commission of a ceramic nativity icon falls into the latter category. From the moment I first laid eyes on it, I knew this would be one of the toughest projects I had ever taken on.

This piece was not just broken—it was hanging on by a miracle. A deep structural crack ran in a full circle around the entire piece, threatening to split it into multiple parts. The only thing keeping it together was the thick ceramic frame, which miraculously survived the impact apart from a totally shattered part at the top of the icon.

This article details the crack consolidation phase—the first crucial step in ensuring that this restoration commission doesn’t end in disaster. If you’re interested in miniature painting, restoration work, or custom commissions, be sure to follow along. And don’t forget, you can explore unique fully painted models and exclusive merch at DressArt3D.com!

The Challenge – A Structural Crack Holding on by a Thread

Why This Restoration Commission Was So Risky

When I first assessed the ceramic nativity icon, I quickly realized I was dealing with a worst-case scenario in ceramic restoration.

The circular structural crack ran from one side to the other, and although the piece was still holding together, the ceramic was shifting slightly along the break line. This meant that any movement—even the slightest mishandling—could result in a complete break. If that happened, putting the pieces back together perfectly would have been nearly impossible.

I had two major concerns:
1️: Applying glue inside the crack wasn’t an option. Since the sculpture was still in one piece, I couldn’t reach the inner break points.
2️: If the bond wasn’t strong enough, the piece could collapse under its own weight. Traditional ceramic glues alone wouldn’t hold up long-term.

I needed a solution that would stabilize the entire piece without breaking it apart further.

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The Plan – An Unconventional but Effective Solution

A Lesson from an Old Teacher

While searching for a way to reinforce the piece, I recalled a technique my electrician teacher once showed me—using medical tape drenched in super glue to create a fiberglass-like reinforcement.

This method works by allowing the super glue to soak into the medical tape, hardening into a rock-solid structure. When properly applied, it can be stronger than regular glue alone and acts as a structural support across the break line.

Given that traditional ceramic repair methods wouldn’t work here, I decided to give this method a shot.

Step-by-Step Process for Crack Consolidation

Step 1 – Applying the First Layer of Super Glue

Since super glue dries quickly, I worked in small sections to ensure the best results:
✅ I applied a thin layer of Wurth’s Super Glue (one of the strongest available) directly along the crack line.
✅ Using an old brush, I spread the glue evenly and to the width that equaled that of the medical tape, making sure to push it into the crack where possible.

Step 2 – Reinforcing with Medical Tape

Once the first glue layer was down, I quickly applied medical bondage tape over the entire crack line before the glue could fully cure:
✅ I pressed the tape firmly into the glue to ensure maximum absorption.
✅ The goal was to let the tape soak up as much glue as possible, creating the first solid bond with the ceramic icon.

Step 3 – Drenching the Tape in Super Glue

This is where the magic happens!
✅ Again, before the first super glue layer dried. I poured another generous layer of super glue over the tape, fully saturating it.
✅ The top and bottom glue layers fused together, locking the tape in place.
✅ This method created a reinforced, fiberglass-like bond, making the crack significantly stronger than glue alone.

Step 4 – Overlapping for Extra Strength

To ensure maximum reinforcement, I repeated the process across the entire back side of the sculpture:
🔹 Overlapping tape strips to create one continuous bond.
🔹 Allowing each layer to fuse together before moving to the next.
🔹 Working slowly and carefully, ensuring everything was secure and fully set.

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Securing the Front Side of the Crack

Since I couldn’t apply the medical tape method to the front, I took a different approach:
✔️ I applied a thin layer of super glue over the entire front crack line.
✔️ This sealed the crack while keeping the surface smooth enough to be sanded later.

This method would allow me to later refinish and paint over the repaired area, helping it blend into the original ceramic finish.

The Waiting Game – Letting the Bond Fully Cure

Once the crack was fully reinforced, I let the piece cure for 48 hours in direct sunlight. This was essential for:
🔹 Ensuring the super glue had fully hardened.
🔹 Letting fumes evaporate before working on the next stage. (SAFETY NOTE: Always wear a mask when working with super glue!)

After two full days, it was time to test if the method had worked.

The Results – A Reinforced and Stable Icon!

After waiting anxiously, I finally tested the piece and was beyond relieved:
✅ The ceramic was completely stable—no shifting or movement.
✅ The crack was reinforced and no longer a weak point.
✅ The sculpture was ready for the next stage of restoration.

This restoration commission was now on track for a full recovery!

What Comes Next? Follow the Full Restoration Commission Journey!

With the crack consolidated, the next phases of the restoration commission will include:
🔹 Sanding & Refinishing the Crack Line – Making the repair as invisible as possible.
🔹 Rebuilding the Missing Frame Section – A huge challenge that will require sculpting and shaping new ceramic-like materials.
🔹 Color Matching & Painting – The hardest part of restoring ceramic surfaces to their original look.

If you love challenging restorations, follow along for the next update!

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Final Thoughts – A Major Step Forward in This Restoration Commission

This ceramic nativity restoration commission is one of the hardest projects I’ve tackled, but this first phase was a success!

What started as a fragile, near-collapsing piece is now structurally sound and ready for further work.

There’s still a long road ahead, but with careful planning and patience, I hope to bring this cherished icon back to a display-worthy state.

Stay tuned for more updates, and thank you for following along on this restoration journey!

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