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The lost wax process is used to create the bronze sculptures. First, the sculpture is created using wax, paper, cloth, and anything else that is combustible.
After the wax sculpture is finished it is gated which creates the channels that the bronze will flow through when it is being poured. Gates must go to all parts of the sculpture to ensure that the bronze will reach them.
After gating, the ceramic shell mold is created by dipping the sculpture into a slurry mixture then coated with 'sand' multiple times. Between each dip the slurry must completely dry.
Next, comes burnout where the mold is heated in a furnace placed over a hole where the melted wax flows out of the mold.
The bronze is heated to over 2000 degrees in a crucible then poured into the mold. After cooling the sculpture is broken out of the mold then sandblasted to ready it for metal work. The gates are cut off and texture is restored by grinding and polishing. During the cooling process the metal shrinks which can cause cracking and tears which must be repaired usually by welding. If the sculpture was cast in several pieces they are welded together.
After the metal work is done the sculpture is ready for patina. All of the oil is removed by washing with dish soap followed by a rapid wipe down with acetone. A combination of cold and hot patinas, antique black, ferric and cupric nitrate are applied layer by layer. Finally, wax is applied and then buffed to bring out the matted finish.
Bronze castings
The castings were done at the West Valley College foundry. David Ogle teaches sculpture and he is leading the process. 'Old Blind John' recorded the videos.
