The process of casting

 

Step 1: prepare your work area.  Get your molds, graphite, metal, gloves, goggles and bucket of sand.  Get all liquids out of the area!

Step 2:  prepare new molds by giving them a spray of graphite.  Every so often ,you will have to spray them again.

Step 3: heat your metal in the hot pot. 

Step 4: Clamp your mold.

Step 5: when the metal is molten and runs fluidly, fill your ladle.

Step 6: pour quickly and carefully into the mold. You may gently tap the filled mold a few times. 

Step 7: set the mold aside for a moment or two.

Step 8: open the mold.  Remove the clamps. Rubbers molds open easily.  Use a screwdriver or knife to pry open metal molds. Use a pliers to remove the casting.  If it cast well, put it aside to cool.  (Just because it is solid does not mean it is cool enough to handle)  A poor casting can be re-melted and reused.   

Step 9: replace clamps.  If your pot is low, add some metal.    Go to Step 5 to cast another piece.

 

 

The process of cleaning a figure

 

Step A: make sure figure is cool.  Begin by removing the mold cone.  Cut 1/16 to 1/8 inch (1 to 3mm) above the point where the cone ends and the figure begins.  Place the cone in your "recycle box” to melt and reuse the next time you cast.

Step B: cut away large pieces of flash.  Put them in the recycle box.

Step C: if the metal is soft enough, cut away pieces of flash with an old knife. 

Step D: trim the fragment of mold cone by filing it off.  Use a rasp and shape it as you file.  Finish with a smaller file, shaping it to fit with the rest of the figure.

Step E: use files to remove remaining flash, burrs, etc.  Smooth the figure so there is no evidence of mold lines, mold cones or other imperfections. Gather all metal bits and put in your recycle box.

Step F: soak the figure to remove oils or other residue.  I soak mine in paint thinner for a few minutes, and then water for a few more.  Allow figure to dry thoroughly.

Step G (optional): some casters run the figure gently with fine steel wool or a fine wire brush to roughen the surface prior to painting.

Step H: drill any holes or make other adjustments you need to make,.

Step I: apply a coat of metal primer.  Allow it to dry thoroughly.  From here, you can paint, assemble, and otherwise work with the figure.