The Process

The Process.

 

Some of the process can be seen throughout the images above:

There are photos of burnout and pour.


The shelled waxes are in burnout phase. 


The photo of the shells on fire are the wax being burned out of the shell thereby leaving the negative image in the shell. 


The glowing shell pieces are further heated to 1600 degrees. 


The heated shells are immediately transferred to the pour bin. 


The bronze has been in the furnace heating to 2300 degrees. 


The crucible with about 150 lbs of bronze is then pulled from the furnace and allowed to cool to the exact temperature that the shell pieces require to be successfully cast. 


Ideal temperatures vary as to the size and thickness of the piece being cast. Smaller thin pieces require different temperatures than large thicker pieces in order for the metal to run completely through the shell for a successful casting. 
After cooling down the shell is carefully air hammered from the bronze casting by hammering consistently at the spruing cup to remove most of the shell. Further removal of shell is accomplished by sandblasting. 


The castings are then chased (imperfections in castings welded and repaired). 
The pieces are then assembled, welded, chased, sandblasted, patinated and finally sealed with wax or lacquer depending on the environment the piece will be exposed to.