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![](http://kraigvarner.com/pictures/process-pic-250/the-casting-process.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/PA120818.jpg) |
A steel armature is fabricated that will function as a â€skeleton†to hold the weight of the clay |
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The piece is sculpted using an oil based clay |
![](http://kraigvarner.com/pictures/process-pic-250/Clay%20(6).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Clay%20(7).jpg) |
The piece is worked and reworked until both the artist and client are pleased |
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The finished life-size sculpture |
![](http://kraigvarner.com/pictures/process-pic-250/Clay-(9).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20261.jpg) |
Thin sheets of metal are used to divide the sculpture in to a predetermined number of sections |
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A latex rubber is applied to the clay sculpture. 5-6 coats are used to build up a sufficient thickness |
![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20271.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20251.jpg) |
The molds are backed with plaster, which will give rigidity and support to the rubber |
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The plaster pieces are removed and the latex is cut down the center to create a two section mold |
![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20292.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20288_1.jpg) |
A finished set of Molds |
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The molds are coated with wax to create a copy of the clay original |
![](http://kraigvarner.com/pictures/process-pic-250/Wax%20Pour%20Finish%20(2).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Wax%20Pour%20Finish%20(11).jpg) |
Wax is poured in, the mold is rotated to evenly coat, and the excess wax is poured out. This will create a hollow replica |
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A finished wax being removed from the mold |
![](http://kraigvarner.com/pictures/process-pic-250/Wax%20Pour%20Finish%20(14).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Wax%20Pour%20Finish%20(15).jpg) |
One finished wax piece |
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The pieces are touched up and wax runners and a wax cup are attached. The cup and runners will later act as funneling system to enable the bronze to reach the piece |
![](http://kraigvarner.com/pictures/process-pic-250/Wax%20Chase%20Finish%20(9).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Slurry%20Finish%20(1).jpg) |
The pieces are coated in a liquid ceramic and allowed to dry. This will be repeated 7-8 times to build a thick ceramic shell. The shell becomes another mold |
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Finishing the first coat |
![](http://kraigvarner.com/pictures/process-pic-250/Slurry%20Finish%20(2).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Slurry%20Finish%20(5).jpg) |
The piece is next coated in sand. This will help dry it quicker and add mass to the ceramic |
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The ceramic is chipped away from the bottom of the cup gaining access to the wax. The piece is heated and the wax melts, leaving a hollow ceramic shell |
![](http://kraigvarner.com/pictures/process-pic-250/Auto%20Clave%20Finish%20(2).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Auto%20Clave%20Finish%20(6).jpg) |
The mold is now hollow and ready for bronze to be poured in |
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20 lbs. bronze ingots will be melted and poured into the shells |
![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Pour%20Finish.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Pour%20Finish%20(3).jpg) |
The bronze is melted in a crucible in a furnace to over 2000 degrees |
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The ceramic shell are also heated, to prevent them from shattering from the shock of the molten bronze |
![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Pour%20Finish%20(11).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Pour%20Finish%20(14).jpg) |
The shells are removed from the oven and place in a sand filled box with the cup facing up |
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The cup acts as a funnel and the runners carry the bronze to the piece |
![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Pour%20Finish%20(17)%20copy.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Chipping%20Finish%20(6).jpg) |
Once cooled, the ceramic shell is chipped away. Then the cup and runners will be cut off |
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A finished set of bronze pieces ready to be reassembled |
![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Chase%20Finish%20(1).jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Metal%20Chase%20Finish%20(4).jpg) |
Using heli-arch welders the bronze pieces are welded back together. The sculpture is ground and polished to create a seamless finish |
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The sculpture is heated and treated with chemicals that oxidize the bronze changing its color to the desired effect |
![](http://kraigvarner.com/pictures/process-pic-250/Foundry%20Process%20Photo's%20091.jpg) |
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![](http://kraigvarner.com/pictures/process-pic-250/Leap-Frog.jpg) |
The finished piece is not only beautiful but strong and durable able to last generations! |