Casting from an original carving #8: Pouring the casting material - the end

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Blog entry by Jordan posted 02-04-2012 07:06 AM 10899 reads 0 times favorited 29 comments Add to Favorites Watch
« Part 7: Breaking the mold Part 8 of Casting from an original carving series Part 9: The bronze »

You seriously didn’t think I could wait until tomorrow did you?

Yep, I got busy right after dinner and just had to see if all of this work paid off and I could indeed pour some wax tomorrow.

Prior to setting the pieces all together, I sprinkled powder onto the design surface of the rubber mold and gave it a good shake. For those of you who don’t know, this is called powder coating. The reason I do this is because after resin is poured, it gives off a shine that is hard to paint. Powder coating not only dulls the surface but the powder draws the resin into the nooks and crannies. I use baby powder because I’m too lazy to look for talc but talc of any kind is fine.

Next I fit the rubber into wherever it matches the plastic – there are many many register marks on the rubber to help you find where it should go. Once I find where it fits exactly, I start to clamp the various pieces using anything that works – some areas only need hand clamps, some need a tie down and some just need a spot of duct tape. You must do this step quite correctly as if you don’t, your cut seams may lose alignment and your casting material will only coat your floor.
I turn the entire mold upside down and look inside to make sure that there is room between the walls to pour material – if they are touching then you’ve put your rubber in wrong. Note, this is a very complicated object to mold so it must be more precise.
Note, it is hard to tell from the picture but remember there is an inside to this project – the vessel floor is just a little lower than the hole

Then bit by bit I mix and pour my resins. I don’t pour large amounts at once because a large weight of liquid could surely stretch your rubber. Smaller amounts dry without creating weight. I finish my pour just a little higher than the collar to allow for any shrinkage or sanding the bottom should it end up a bit lopsided.

When the resin is completely hardened and the whole item is cool to the touch, I remove all of the jackets and my casting is complete. I was lucky, there were so few trim lines but if there is seepage resin, it is easily sanded off. Do you notice how taking a mold from both inside and out gave such a nice texture to the inside of this vessel?

Then I gave myself a big pat on the back and had a pastry!!!! Tomorrow I will cast it in wax and the next time you see this vessel it will be in bronze.

Just in case you’re wondering – the resin was only a test to see how the mold was working. After seeing it worked, I will now pour WAX into the mold. The wax will be coated with concrete at the foundry then placed into a kiln where the wax will drip out of the concrete and leave a void where molten bronze will take the place of my wax model. This is called the lost wax process. My mold will only ever be used for wax or resin, not anything hot.

Thank you so much for your interest and please feel free to email me if you require any help with your project


29 comments so far

View longgone's profile


5688 posts in 3916 days

#1 posted 02-04-2012 07:17 AM

That is a truly an amazing process you have done Jordan…Outstanding all the way…Until your last photo I did not realize how large that gourd is.

View Jordan's profile


1400 posts in 3732 days

#2 posted 02-04-2012 07:21 AM

It took 12 cups of resin Greg. It’s heavy too. I’m tired now, happy but tired.


View Joe Lyddon's profile

Joe Lyddon

10869 posts in 4660 days

#3 posted 02-04-2012 07:29 AM

Jordan, that was an absolutely awesome experience!!

It’s wonderful how you can DO all of that!!

OK, you’re going to make a Wax copy…

From that they make a Bronze?
Won’t the hot metal melt the wax?

Thanks again!
It was GREAT!
You were GREAT!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View lightweightladylefty's profile


3471 posts in 4320 days

#4 posted 02-04-2012 07:32 AM


We think we finally caught on after going through the whole thing—not that we would ever be so amibitious to try this! It certainly entails a lot of work.

We, too, were surprised at how huge your vase is. Thanks for taking us on your journey.


-- Jesus is the ONLY reason for ANY season.

View patron's profile


13694 posts in 3948 days

#5 posted 02-04-2012 07:50 AM

you thought we would sleep ?

knowing you are so close
and knowing you just might do it tonight

what a great series jordan

and the work is outstanding !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View majeagle1's profile


1426 posts in 4104 days

#6 posted 02-04-2012 07:53 AM

What a journey…..... just amazing! I, like greg, did not realize just how big this was. WOW, I can just imagine the weight when it is done in bronze! Can’t wait to see the end results.

Your work is just amazing Jordon, such talent….... I would love to come learn from you !

-- Gene, Majestic Eagle Woodworks,,

View lanwater's profile


3113 posts in 3542 days

#7 posted 02-04-2012 08:11 AM

I am glad I checked one more time before retiring for the night.
It would have been like missing the fireworks during the 4th of july…

It has been a great learning experience with a very talented teacher.

Thank you!

-- Abbas, Castro Valley, CA

View Jordan's profile


1400 posts in 3732 days

#8 posted 02-04-2012 08:12 AM

In case you wondered, like Joe, the wax will be dipped in concrete at the foundry then it will be put in a kiln until it all melts out – the concrete will then be filled with hot metal thus the term – lost wax method.

Thanks everyone, you think I would’ve just been happy enough to carve gourds but oh no, I had to take it to the limits!!!!! I hope they’re worth the effort.


View Moron's profile


5046 posts in 4501 days

#9 posted 02-04-2012 08:17 AM

am I missing something ?

so now, your going to pour molten bronze in that mould ?

is there another step ?

-- "Good artists borrow, great artists steal”…..Picasso

View Jimthecarver's profile


1124 posts in 4393 days

#10 posted 02-04-2012 02:11 PM

Wow, Indeed you da man for sure.
Great blog….and as mentioned above, I too was suprised of the size of the gourd.
I think you should be able to record the foundry process to share, but I doubt they would allow that.
How difficult will it be to remove it from the wax w/o damage to the object after cast in wax?

-- Can't never could do anything, to try is to advance.

View nonickswood's profile


561 posts in 2995 days

#11 posted 02-04-2012 02:37 PM

Excellent Jordan!
What a process but truly worth all the effort.
Cast it in GOLD!!

-- Nick, Virginia,

View Karson's profile


35210 posts in 5008 days

#12 posted 02-04-2012 02:55 PM

Jordon: That is big. But a beautiful job. Good luck on the next step.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View HalDougherty's profile


1820 posts in 3844 days

#13 posted 02-04-2012 03:25 PM

I like the way you’ve documented the process for creating your art, making the mold, and pouring a test casting. I look forward to seeing the result in bronze. It’s going to look fantastic.

-- Hal, Tennessee

View SPalm's profile


5334 posts in 4489 days

#14 posted 02-04-2012 03:52 PM

Wow. That sucker is huge.
Thanks Jordan, this has been very informative.

I too am still a little confused. It this resin piece the wax vessel that will be cased in concrete and lost? Or is there another male/female cast made? Can you make another of these resin pieces from that same rubber mold?


-- -- I'm no rocket surgeon

View Jordan's profile


1400 posts in 3732 days

#15 posted 02-04-2012 06:06 PM

Hal, I’ve added a footnote to the photo re the wax process.

Steve, yes each time I have to replace all of the plastic supports as especially the inside of the mold is floppy and wants to move around.

Now Gold…whoa, that would be something? Anyone willing to donate their gold crowns?


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