chyancarrek

Our total cycle takes about 36 +/- hrs for a full kiln ( around a ton +/- of molds). The first 10 hrs are a slow rise through 850 degrees then holding around 1000 - 1100 degrees for about 24 hrs +/-. (don't exceed 1100 for any length of time - it's a good way to burn up your molds) Cool down is around 15 hrs but that's a bit arbitrary as we never empty the kiln right away. We're not doing production work so generally we don't start to pour until the following week. The most important part of the cycle is the beginning - you want to make sure that your molds don't move through 400 degrees until the majority of the wax has flowed - it's the steaming out of the moisture which removes most of the wax and to take it above 400 - 500 too quickly results in a quick rush of wax into an environment where it will catch fire inside the kiln - that can get kind o' exciting pretty quickly You'll notice I've got a lot of +/- in those numbers. What we do is based on how we know it works with a set up that's been in use for 50 yrs so we're not taking ongoing measurements. There's a lot of "looks right, smells right, feels right" going on so I'd definitely recommend doing some research and lots of experimenting based on what kind of set up you are using.

Hey Senft, We do our investment in 250 lbs batches - the mix is really simple: 70 lbs 70grit silica sand 70 lbs 30grit silica sand 100 lbs pottery plaster 8-10 lbs perlite. You can break that down into ratios to give yourself any sized batch. Please note - this is a mix (no matter how large or small the batch) that will give you a really rough texture - we mix this way because of the size and weights of what we pour and because the surface detail that Jim put's on his work is very organic/earthy. Part of our process of surface prep involves heavy and aggressive grinding and sanding. I've attached a couple of pics (one right out of the mold - the other right prior to final surface prep) to give you an idea of what it looks like.. Hope this helps!

Welcome to IFI Stabber! Looks like you're off to a great start!

The studio in the pics belongs to my friend James Lee Hansen an 84 y/o sculptor I've been working with for the last 12 years. Jim's an amazing fella, he does large scale abstracts and even at his age you just can't keep him out of the studio. We've got a pretty good cadre of friends across the spectrum of experience (ace welders, fabricators, riggers etc) and so with our help he continues to produce more work. I'm his "right-hand man" and handle most of the production aspects for the bronze work as well as all of the database work and photography for his catalog raisonne'. Fe, The trolly kiln has sure seen it's share of use - out of the pictures to the left is another one that's almost twice the size of the one pictured. We'll be pouring bronze for 4 new pieces. Michael, You're spot on - The two SS pieces in the pics are the first one's that Jim has done in about 8 years and he's very excited with how they're coming along. Most of his work is cast from bronze as components then assembled into the finished piece. He has a website in progress here's the address: www.jamesleehansen.com/index.php The portfolio section features mostly smaller work as we're still in the process of getting updated photography for his larger work at the studio and in situ. If you do a google search on his name, you'll find all sorts of pics and info about his work. He's been doing this for over 60 years and he's got an amazing history! Senft, What we're doing in the pics is straight-up poured investment were the wax is suspended in the mold form and material is poured surrounding the wax. It's a simple mix of silica sand, perlite and pottery plaster. Shell casting is more oriented towards faster volume production and uses a harder curing material where the wax is dipped repeatedly into the investment building up successive layers. I'll post some more pics as we move along!

Some days are just better than others - getting together with some buddies to work on a couple of welded pieces then setting up the first of three kiln loads for an upcoming pour.

Looks good Creek! Hey, if it's working for you, thats all the justification needed! Thanks for sharing the pics.

Hey Jeff, You're still on the list here! Hang in there buddy - it's gonna get better!

Nice job on the stand Creek! Post some shots of the block in it when you start using the stand and let us know how it does for you. When I was smithing at Ft Vancouver we had a stand similar to Judson's - A wooden beam buried in the dirt floor of the shop but the slot was a tad shallower to make it easy to change it's orientation. Currently I just set mine on a pedestal turntable that has a 1/2" steel plate for a top. It works well for me because most of my work is small scale so no heavy hitting occurs. I can just set it upright on whatever edge is needed or laying flat to do sinking work for hammered vessels.

Dang Mike, Thats the sort o' thing that could scar a kid for life! So . . . . was the hen a good fryer?

Hey Mike, All of the responses above pretty much have you covered so as far as what to do - it sounds like you're well on the way with some good advice. The only thing I'll give a second to is either go with a tractor coop/foraging unit or free range them and just factor in predatory/elements loss. Keeping all o' the birds in one place all of the time means really having to monitor the health issues and flock infections/infestations - they can happen quick and be devastating if you're not on top of it. For myself - I hate em! The only thing good about a chicken is eating it! As a kid my family kept a roost of about 50 and we also raised about 200 game-birds for the game dept's release program every year (ring neck pheasants and chukkars). The only thing dumber than a chicken is a ring-neck pheasant - I know, I know, they're all "clever" and they can do some o' so entertaining things but just the idea of having them around gives me the willies! I'm so glad that all I have to do is make some fun ironwork for the neighbor who has a roost and I get clean fresh birds and eggs ready for the frying pan All that being said - have fun you're in for a "great" eggsperience!

It was a 50 lb LG for me - I used it for the first time at Powerland in Brooks Or in 2001 - I remember thinking - "man, I can move some metal with this" then stayed away from PH's completely because I saw it as a threat to developing my hand hammering techniques. Maybe that was a bit of an odd perspective, but I'm glad I stuck with the ol' arm & hammer for the next couple of years. I now have an 85 lb pneumatic hammer that was built by a fellow NWBA member (Bert Romans) and I love how it continues to open up the possibilities for much more dynamic forging as well as giving the arms a needed rest doing the heavy hammering of drawing out and texturing my work.

I'm not too fond of the foam plugs myself. I've known a couple of fellows who had troubles with "junkitis" of the ear because they didn't keep the ol' canals clean before they inserted the plugs and they didn't seem to get the concept that they're fairly cheap so you don't have to use the same pair repeatedly. I use a set of muffs that have an FM radio in them - I keep it at low level so I can hear what's going on around me but still enjoy my ipod (it has an FM transmitter on it).

When the kids bring their friends over to show off the fact that you can flip steaks and burgers on the grill with your bare hands

Keith, Our sincerest condolences for your loss! My GF and I send all our best thoughts to you and your family!

Brian, Thanks for posting this! For myself, I'm not fond of using or making tongs and do everything I can to keep the metal in my hands for as long as I can. I'm always on the look out for a set that crosses many uses and shapes and yours sure look like they'll fit the bill. I'll definitely be making some of these for my shop.

I've always called my shop a shop, but sad to say, YD's right - Heaven knows that along with the actual work that comes out of our efforts, we also have to sell the "mood" of the whole art mystique so that the client can have a vicarious creative experience.

I've got several different types including face shields but my favorites are glasses that my dad had - He worked in a foundry for 35 years and after he passed away I found several pair that I now use. Thick lenses, black heavy frames with fine mesh screen at the temples. My GF refers to them as "BCG's" but no matter how they look, they sure can take a lot of abuse and are darn near impossible to scratch or chip.

Oh man, that's got a pucker-factor of about 11.5 on a scale of 1 to 10 . . . I got a thing about heights. I'm thinking a couple of young fellas better be on their knees giving thanks!

Hey Johnnie, Now that work is just ducky! (sorry - couldn't resist). I'm with Frosty, the seat is fun but I'm liking your forge work more. I will say though, with that seat being JD yellow & green, I got a buddy of mine who would abscond with it in a heartbeat!

Yowwwch! That hurts just hearing about it. Glad you got to keep your digit! My only major hand boo-boo was getting tangled up in a frisky young colt's halter when I was turning him out. It popped the knuckle on my R/ring finger real good. I thought I'd just dislocated it so I yanked on it, got a pretty good pop out of it and went back to finishing chores. Got up the next morning and it was double sized and black as midnight - fast forward to the next day (after taking a thumpin' from the wife for not going in right away) and I'm in surgery watching the doc remove the 4 pieces I'd shattered the knuckle into. He fixed them up nice and tidy like ( with a little grinding here - drill a hole or two there) and voila! - Not so good as new. That finger is now at an angle where I can finally do that Mr Spock "Live long & Prosper" thing with no trouble at all!

Hey Fe - Can-do on the labels . . . you're on your own for a bottle (or three) to stick em' on!

Just goes to show that the lads in Australia have a firm grasp on how to give proper respect to the craft! I'm more of a distilled spirits kind of guy and not having found any labels on the harder stuff that pays homage, I decided to make a few of my own. These have been real popular with my blacksmithing buddies and I've donated a number of them (affixed to a proper bottle of spirits of course) to the NWBA's conference auctions.

That's real nice looking work Stretch! Great proportions and detailing! Are you installing on the doors? If so, take a pic or two!

Welcome to IFI Paul! You've come to the right place - you'll find all sorts of great info and some real nice folk! One warning though . . . this forum can be addicting! Enjoy!

Ok, I'll break into the bike lovefest . . . Taken 15 years ago - C-130 at a local airshow. The pilot was a buddy of mine so we hung out in the cockpit shootin' the breeze. Taken last year - I love old iron but I prefer 4 wheels under me - My '50 3/4 ton Chevy Taken 8 years ago - Two A**ses heading down the beach - My boy Mac Larry, Now I recognize your mug!