[TheForge] How is something like this made?

[Mike Porter]

Jeff,
Isn't the question you meant to ask "what is the practical way to make
something like this? After all, it can be fabricated in many ways; some of
which are hilariously inappropriate. Common sense dictates that you would be
looking for the "bottom line" about its construction.

That bottom line is CASTING. After creating a wooden pattern or a wax model
(depending on whether you were doing a one-off part or intending to make
many of them), you would proceed to cast it, or send it to a foundry if you
had the $$$$$ to spend. Next, you would clean up the casting
(sanding/filing), and then do the drilling, threading, mounting a handle, or
even chasing, in accordance with your available tooling. But the bulk of the
construction is a matter of foundry work.

Casting; what a scary thought...or perhaps not. The metal for a part like
this can be liquefied in a jewelers furnace (tabletop equipment), and cast
into sand or plaster molds. How much equipment you need--and how much
experience--only depends on how picky you wish to be about the cast part; in
other words, it is merely a question of where you wish to expend your
energy; in equipment & preparation, or in extra finish work?

Why then is casting such a daunting idea for most of us? Simply because we
build it up in our minds. The IT of which I speak is the whole commitment;
or at least our visualization of such a commitment. In reality, how much of
a chore every aspect of foundry work becomes, depends directly on SIZE. The
nearly universal mistake is made in thinking big. What you want to do is
think small. No matter how great your ambitions become casting wise, small
equipment goes right on being used. The same cannot be said of large
equipment. In fact, large equipment, like the LARGE mental images of foundry
work, is what usually stops people from getting anywhere with it.

Furnace equipment construction was included in Gas Burners with the idea of
blacksmiths casting their own finials, fancy lockbox plates, handles,
escutcheons, and other detail work, to set off the bulk of their ironwork in
bronze and pewter. Of course, casting is one more learning process, just
like all the other learning processes an artist must face. On the other
hand, the benefits can far outweigh the struggle for any young smith.
Visualize a scroll panel (say four to six scrolls forming a basic design).
Mentally connect them by welding; not so hot. How about connecting them with
forged bands; more visual interest here. Finally, set them together two at a
time, within your personally designed mold, and pour your bronze or pewter
connectors. Picture the cast connections as simple or fancy as you wish,
because that is what casting is all about. Or, how about cast bronze center
pieces in twisted pickets, and one-of-a-kind cast lambs tails? Bronze or
pewter handles on forged fireplace equipment (let alone all the other
detailing for a fancy fireplace screen, etc.) Need I say more? OK, than
consider iron furniture with cast bronze connectors instead of the cheap
cast iron used a century ago; suddenly, an old idea is updated into
usefulness with today's blacksmithing projects.

Naturally, there is another worry that springs to mind; "what if I get so
involved in this foundry stuff, that I'm sidetracked, forgetting about my
blacksmithing?" That is a legitimate concern, and all I can give you by way
of reassurance is that this particular "sidetrack" is quite lucrative. Just
input bronze sculptures on eBay and look at the prices. No, I don't mean
garden sculptures; these are of a size to be poured from a tabletop furnace.
You can hold many of them in one hand.
Mikey

-----Original Message-----
From: theforge-bounces at mailman.qth.net
[mailto:theforge-bounces at mailman.qth.net] On Behalf Of Jeffrey Polaski
Sent: Wednesday, June 14, 2006 1:24 PM
To: theforge at mailman.qth.net
Subject: [TheForge] How is something like this made?

I was looking around some antique watch sites and came across a link to
this antique medical instrument site... I've been wondering how
something this ornate gets made... especially the brace and saw. 

Would it be roughly forged and then the flat shapes filed? Or is it a
lot of swage work, with male & female dies to match?

Has someone made something like this before? 

I've been really curious about how the more ornate and "fine" stuff is
made, for example, European tools with little sculptures in them. It's
amazing that people can do that at all. I can barely bash out a little
dragon head, let alone a full iron cherub! How do they do that? I know
some things are cast, but how do people make forged sculptures?

Here's some examples:

<http://antiquescientifica.com/saw_amputation_c_1750.jpg>

<http://antiquescientifica.com/neurosurgery__trepanning_set__Lichtenberg
er_Strasbourg_out.jpg>

I can't find a good example of the European tools I was thinking of, but
I think almost everyone has seen pictures of vices or anvils with ornate
scenes on the side. 


Jeff Polaski
Research and Graduate Studies Webmaster
University of California, Irvine
http://www.rgs.uci.edu/
949.824.6363


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