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The Making and Process of

The manufacture process:
This will show you the length and the complexities of casting what can bee seen as such a simple shape and object. 
The mould is a 16 part mould and has 10 cores in total. The approx wieght of the piece is 300-400kg, measuring 1200x1200x290mm and is cast out one solid piece of iron.

pattern is made from 19mm resin coated plywood. anchor plates are then added for lifting and removing.
ready to go!!
the side are built up with a taper so that they will give the pattern slack to be removed.
the two other side are added and the inner cores for the feet are added.
parting powder is then added so that the next stage of sand does not stick to each other.
the top is then added with its sprue and gates added with a centre 'knockout' hole if need for removing the pattern. 
the anchors hook holes are placed in for the cores to bolt through 
The top is spiked to let the fumes and gasses escape from the sand
the top is then sanded and forms are removed.
it is all then rotated round and the locators are removed, sanded and blown off.
the centre of the patern is then filled with two sections on either side, these have slopes so that they can be removed and put back together in reverse order.
all six core on top also have anchor hooks so that they can be hooked on the bottom piece holding them in place and stopping them from floating when metal is poured.
this is all then covered in parting powder and then rammed up as earlier.
all is then split and cores are removed.
the pattern is then removed  using the anchor plated on the pattern.
(the top of the mould once removed)
the top of the mould with the six cores glued and anchor hooked in place.
the cores in the base are then pinned in place using 7 inch nails 
(core is scored and then slid in and nailed into the opposite facing side)
sand is then rubbed all over and pressed into any gaps and cracks
(top and bottom)
the excess sand that is rubbed into the cracks is then sanded and blown off
(top and bottom)
'blacking' is added by painting on a mix of graphite and ethanol 
this protects the sand from burning and braking down with the thermal shock.
'blacking' also gives a smoother finish.
the excess ethanol of the 'blacking' requires burning off  by lighting.
after the 'blacking' is burnt and gone hard.
the above 'blacking' process is then repeated on the top of the mould
weights are then added to the last two cores on the top as they lock the other four in place. 
the weights hold the glues as its setting, for a stronger bond.
spacer plates are then added to the base so that when to two halves are placed together they don't fall together and to prevent and floating of cores.
the two halves are then turned and put on top of one another.
the gate were the metal is pour has a filter added
the risers are then added, this is were the air rises out as the metal goes in
the riser are then packed round is sand to prevent any leaking or  cracking of the sand during the curing stages. weights are then p[laced on top to prevent the two parts of the mould opening when metal is poured.
the cast is the knocked out and sand blasted to clean off all the sand that has burnt to in the extreme heat.
after blasting it is then 'fettled'. ie the runners, gate and risers are chopped of and any imperfections taken care off.




Extras made for 'Skilled Hands'

the cast of the tools are exact copies of the tools that were used to make the  sand pit to 'Skilled Hands' as can be seen in some of the image above. the tools have been made using the same process as the pit but in a two part split mould. the tools will be inside the sand pit with the intention of being handled and interacted with.





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