Artwork by Gary |
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 2. Covering the guy with sculpting wax. |
 3.Then it's time to apply the clay. |
 4. Then it's time to get to work. |
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 6. Working on the hands are the toughest part. |
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 8. Now working on the pants. |
 9. BB's make good beadwork. |
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 11. Several hours later - hand and gun are one. |
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 13. I apply heat & drag the clay to create a heavy plastered effect. |
 14. Just a few of the details. |
 15. The final product - ready for the foundry. |
After my work is done the sculpture was loaded into the back of a horse trailer and delivered to Northwest Art Casting www.nwartcasting.com in Bozeman, Montana. The following photos will show you the "lost wax method" of casting a bronze sculpture, from the mold process all the way to dedication day.
If you would like me to remind you when new photos have been posted just send me a quick e-mail so I have your address and I'd be happy to keep you up to date.
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 1. The Foundry process begins!! First the arms and extra details are removed and he's divided into sections in preparation for the mold. |
 2. Mold maker "Matt" applies the first layer of ruber to the piece. |
 3. Sculpture is completely covered in rubber and ready for plaster. |
 4. After 3 coats of rubber the plaster is applied to support the entire structure. |
 5. Matt & Mitch work hard to finish the plaster. |
 6. After the mold is cut apart and the clay original is discarded, Ben pours a layer of wax into the mold recreating the original. |
 7. Shawna repairs any imperfections in one of the wax arms. This is called wax chasing. |
 8. Jeff dips the wax reproduction in a slurry so silica sand will stick. |
 9. Jeff covers the wax reproduction with sand to create a shell. When the shell dries it will be heated to melt the wax out, creating a void, to be replaced by molton metal. |
 10. Matt and Josh heat bronze metal to 2000 degrees, pour it into the shell and wait for it to cool. |
 11. After the bronze has cooled the shell is removed with a hammer and the rest by sandblasting. |
 12. The process of welding all of the cast pieces together begins. The sculpture is laid on its side to weld the leg. |
 13. This step is called bronze chasing. Tyler uses a small grinder to remove any imperfections from the surface of the sculpture |
 14. Tyler now sandblasts the entire sculpture which takes off all color that was created by welding, grinding and oxidation |
 15. The patina process begins! Tyler sprays the entire sculpture with potash until it turns black. |
Patina is the color that is created when a liquid chemical is applied to heated bronze metal. For example - Potash makes bronze turn black, Ferric Oxide creates red and Titanium Dioxide creates white. |
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 16. Paul wipes the entire sculpture down with a scouring pad to reveal the bronze color, leaving the dark color in the nooks and crannies. |
 17. Paul heats the sculpture so the liquid chemical will stay where it's applied. If he didn't, it would just make a mess. |
 18. He applies chemicals to the heated bronze which causes a chemical reaction. In this case, red is the result. |
 19. Paul applies more heat and layers one chemical over another to create the colors for the bead and quill work of the tobacco pouch. |
 20. With the patina process complete, Paul sprays the piece with lacquer and then gives it a coat of wax. When the wax cools it will be buffed, just like a pair of shoes. |
 21. After transporting the sculpture from Bozeman to the Shields Valley in a pickup, Joe lowers him to the ground with Seth's help |
 22. Welcome to the Shields |
 23. Jeff begins the rock work on the concrete foundation. |
 24. The rock work is complete. Now we wait for dedication day on June 16, 2007. |
A big thank you to everyone at Northwest Art Casting for their fine work! At the beginning of the 2006 school year I held a NAME THE MOUNTAIN MAN CONTEST for the students at Shields Valley Elementary - grades 1 - 6 in Wilsall, Montana where each class chose one name. In mid September four impartial judges and I chose from 6 great names. And the winning Mountain Man name was............
"THUNDER JACK"
Named by the 1st grade class
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Gary Kerby Art, WILSALL MONTANA 59086
E-MAIL: GaryKerbyArt@aol.com
© Gary Kerby. All rights reserved.