The Basic Process...

Step One: Inspiration

Step Two: Creation.

Step Three: Bronze Casting

Step Four: Presentation

The Detailed Process...

1. The look is agreed to. Often a picture is the basis.

2. An internal steel armature is welded for strength.

4. Non hardening clay is added to finish the shape.

5. The final shape is complete.

6. Molds are made in 2 sections. Flexible for the surface and rigid to support the flexible in the proper shape.

7. Wax is poured and painted into molds 3/16 thick.

8. Wax removed from molds.

9. Wax sections are “welded” together.

10. Wax sections are dipped in silica solution.

11. While wet, silica powder is sprinkled. This is repeated many times to get a thick fireproof shell over the wax.

12. Completed shells.

13. Shells placed in furnace to melt out wax and leave a hollow place to pour bronze.

14. Bronze poured into the shells at approximately 2000 degrees. This is the fun part!

15. After removing shell material the individual bronze sections are welded together.

16. The welds are carefully ground and sanded to hide their existence.

17. Final sandblasting removes oils from fingerprints and bares the metal for coloring chemicals.

18. A “patina” (color) is achieved by the use of acids and heat. This takes real skill to get the desired colors. Splashes of cold water freezes the color is it is right.

19. Assuming the color is right a coat of wax is added while the sculpture is hot so the wax can penetrate the meta as well as possible to retard corrosion.

20. The work of creating a base and the setting of the sculpture in its place is done.