Extensions for apertures in panels

A panel-forming system comprising:

• a plurality of bulkheads configured to be placed on a panel-forming surface, said bulkheads comprising a first group and a second group, said first group arranged in the shape of a panel to be formed, said second group configured to be disposed substantially within a shape formed by said first group such that, upon formation of a panel with dimensions bounded by said first group and said second group, an aperture becomes defined in a space substantially surrounded by said second group;
• and
• at least one aperture extension comprising:
• a bulkhead-engaging portion configured to contact said bulkhead;
• and
• a recess portion extending laterally from said bulkhead-engaging portion such that upon formation of said panel, a pattern becomes defined therein by surfaces on said aperture extension that are configured to face said panel, said recess portion defining a height dimension and an elongate lateral dimension extending from a proximal end to a distal end, said proximal end disposed closer to said bulkhead-engaging portion than said distal end, said elongate lateral dimension being substantially greater than said height dimension;
• and
• an extension cap configured to engage said distal end of said recess portion.

A panel-forming system comprising:

• a plurality of bulkheads configured to be placed on a panel-forming surface, said bulkheads comprising a first group and a second group, said first group arranged in the shape of a panel to be formed, said second group configured to be disposed substantially within a shape formed by said first group such that, upon formation of a panel with dimensions bounded by said first group and said second group, an aperture becomes defined in a space substantially surrounded by said second group;
• and
• at least one aperture extension comprising:
• a bulkhead-engaging portion configured to contact said bulkhead;
• and
• a recess portion extending laterally from said bulkhead-engaging portion such that upon formation of said panel, a pattern becomes defined therein by surfaces on said aperture extension that are configured to face said panel, said recess portion defining a height dimension and an elongate lateral dimension extending from a proximal end to a distal end, said proximal end disposed closer to said bulkhead-engaging portion than said distal end, said elongate lateral dimension being substantially greater than said height dimension;
• an intermediate configured to engage said distal end of said recess portion;
• and
• an extension cap configured to engage said intermediate.

A panel-forming system comprising:

• a plurality of bulkheads configured to be placed on a panel-forming surface, said bulkheads comprising a first group and a second group, said first group arranged in the shape of a panel to be formed, said second group configured to be disposed substantially within a shape formed by said first group such that, upon formation of a panel with dimensions bounded by said first group and said second group, an aperture becomes defined in a space substantially surrounded by said second group;
• and
• at least one aperture extension comprising:
• a bulkhead-engaging portion configured to contact said bulkhead;
• and
• a multifaceted recess portion extending laterally from said bulkhead-engaging portion such that upon formation of said panel, a pattern becomes defined therein by surfaces on said aperture extension that are configured to face said panel, said multifaceted recess portion defining a height dimension, an elongate lateral dimension extending from a proximal end to a distal end, and a longitudinal dimension mutually orthogonal to both said height and lateral dimensions.

A method of forming an aperture in a panel, said method comprising:

• arranging a plurality of bulkheads on a casting surface to form a mold, said bulkheads comprising a first group and a second group, said first group arranged in the shape of a panel to be formed, said second group arranged such that it is substantially disposed within said shape formed by said first group and defines at least one aperture in a space substantially surrounded by said second group;
• configuring an aperture extension to comprise:
• a bulkhead-engaging portion configured to contact said bulkhead;
• and
• at least one recess portion extending laterally from said bulkhead-engaging portion such that upon formation of said panel, a pattern becomes defined therein by surfaces on said aperture extension that are configured to face said panel, said recess portion defining a height dimension and an elongate lateral dimension extending from a proximal end to a distal end, said proximal end disposed closer to said bulkhead-engaging portion than said distal end, said lateral dimension being substantially greater than said height dimension;
• coupling said aperture extension to at least one bulkhead from said second group;
• and
• pouring uncured casting material into a mold defined by said bulkheads such that, upon formation of a panel with dimensions bounded by said first group and said second group, an aperture becomes defined in a space substantially surrounded by said second group.