1. Lost Wax Process: paperboard is cut to the shape of the gate and used like a canvas as wax is applied with putty knife and brush to create the textural surfaces.
2. Being too large to cast in one piece, each wax gate is cut into 9 pieces and gated for casting.
2. Being too large to cast in one piece, each wax gate is cut into 9 pieces and gated for casting.
3. The investment-molds that hold the wax parts are prepared for casting while the bronze ingots are brought on deck to enter the furnace.
4. The Pour: The bronze is ready to pour at a heat of 2000 degrees. The crucible glows bright orange as the molten metal is poured by hand into the molds.
4. The Pour: The bronze is ready to pour at a heat of 2000 degrees. The crucible glows bright orange as the molten metal is poured by hand into the molds.
5. After the bronze parts are “broken-out” from the investments they are cleaned, finished, and pieced together like a jigsaw puzzle.
6. Welding: With the parts fit together, beads are run to connect the parts back into a whole. Through extensive finishing-work, the welded areas are blended into the texture of the gate.
6. Welding: With the parts fit together, beads are run to connect the parts back into a whole. Through extensive finishing-work, the welded areas are blended into the texture of the gate.