Creating a condor to be cast in bronze

RoundRiver · #1 08-18-2006, 12:26 PM

Hello fellow carvers,

This weekend I recieved word boeing has commissioned me to create a 20" bronze of an Adean Condor. Some of you may have view the 48" wooden original in my gallery. This was the first for Boeing....However they really want a male condor and aparently mine was a female. So instead of adding the male parts, I will create the bronze.

This will be my first bronze, and the process is new to me. I will be taking photos through out the process and posting them for you all to see. I will be using a comination of wood, copper wire, tinfoil, and sculpie to create this sculpture. after it is complete it's off to the foundry to be molded and cast.

The project will take about 7 days carving and 8 to 10 at the foundry. Any pointers along the way are appreciated, and I hope we all can learn together!

First pics to come sunday or monday,

Thanks,

Russell
Round River Studio

Tarik · #2 08-18-2006, 12:55 PM

I've never seen how a bronze is made.
Please take lots and lots of photos, I'm expectant for updates.

And... Congratulations!!!!

Ashbys · #3 08-18-2006, 12:59 PM

If I were you ,

I would contact the investment casting house that will be doing the cast. Unlike the bronze made in the lost wax process of 100 of years ago , bronze casting is a normal production process. There is nothing special or exotic about the process.
Today it is refered to as investment casting. The term "lost wax" simply refers to the wax model that is melted and dumped out of the mold before the the metal is poured in. I would assume that they wish to have at least 3 pours into molds to insure they get the proper cavity fill.
I would check with them to find our what they want the model in. You may find out you need a clay model. So they can produce a working model to be used. I would also make sure that the orginial model and all patterns made from the model are to be returned to you after the cast is made, or you may well find your bird around the world in a mater of weeks.
I would also be sure your looking at a investment casting house for the bronze. Becasuse if it is sand casting you might well find out your bronze will not be of the quality you expect.

Ash

RoundRiver · #4 08-18-2006, 01:19 PM

Thank-You Ash,

I'm creating out of sculpy for the sole purpose keeping my original intact through the casting process. As you know a wax would be lost. I plan to guild (in 24K gold) the original and add it to my collection!

As for the foundry concerns thanks for the heads up. I will be using a company out of Joseph, Oregon they are highly recomended for this type of work, and are friends.

thanks again, it seems as you will be a great resource on this project,

russ

Thor · #5 08-26-2006, 08:48 AM

I will look forward to watching the process too. I have toured a large commercial art foundry in New Mexico, and it was amazing. All of the originals that I saw them working with was plastina (oil based clay on metal armatures). The detail and patinas they achieve there are incredible.

You may want to check out these brief descriptions of mediums available before you commit to sculpy. (link below) It's usually used for very small projects and baked in an oven to become permanently hard.

http://www.fxsupply.com/materials/clay.html

What a great commission! Kudos to you.
Thor

Hi_Ho_Sliver · #6 08-26-2006, 09:02 AM

If you are not aware, you may want to asking the foundry if they want "spues" on your original, tubes attached at high and low spots that allow air pockets to escape when the casting material is poured in, otherwise you end up with ends of extremities missing.

Lynn O. Doughty · #7 08-26-2006, 12:31 PM

Sculpy? I'd advise you to forget that medium and go buy you some good plasticine clay. Then, if you're around an area that has a few sculptors, I highly suggest paying one a visit to see how a professional goes about constructing the armature, etc., and how he or she works with the foundry to complete the project.

The "lost wax" process takes place in the foundry so don't be concerned by that area of the bronze process. All you should be concerned about is doing the sculpture in a medium that the foundry can work with, i.e., clay. Once the boys at the foundry get it it will probably be sectioned up to allow molds to be made. Depending on the action and form of the piece any number of seperate molds might be needed.

I did a small pair of cowboy boots once and it took three seperate molds....one for each boot and one for the base. Once cast and chased they were welded back together in the position of the original model before the patina was applied.

One thing you should be aware of is the costs involved. Hopefully, they are giving you some money up front as the bronze process is VERY EXPENSIVE!!!

A good thing to remember is that creating a bronze work of art is no different than the same steps Ford Motor Corp. takes in manufacturing a new crankshaft. A model is made, a mold is taken, a copy is produced from hot metal. and any rough spots are sanded or machined off. It's that simple!

Good luck and keep us all posted about your progress!

Lynn O. Doughty · #8 08-26-2006, 12:44 PM

Check out this site to get a good overall look at the Bronze Process.

www.andrewdevries.com

RoundRiver · #9 08-29-2006, 08:58 PM

O.K. I'm back!

Thank-You all for the wise words so far. After some diliberation, and a jive session with my mentor/bronze guru (leo Osborne). I have decided to rethink the sculpy start. I will however loose the original, but overall I feel the new attack will yield a better product, with less work.

Now the armiture will be made of foam 2" thick, layered, glued, and carved.
After thefoam base is close to the shape I'm after I will cover it and detail with an oil based clay.(thanks Lynn O D) I ordered it from a company called chevant.

Well today I started carving the foam using hand saws and rasps. The attached pictures show the progress.

I should have more by Wed. evening.

Well thats all for now, Untill tomarrow,

Russell

Lynn O. Doughty · #10 08-30-2006, 08:17 AM

Looks like your well on your way. That clay, while seemingly too hard to work with when you first pick up a chunk will turn to an almost pizzadough consistency once you warm it up with your hands.

While in Santa Fe for the Indian Market I spent several hours watching some of the top sculptors in the U.S. work. Really inspiring.