The first thing we do the day of a pour is double check each piece and make sure all cracks are patched. Then we calculate how many pounds of bronze we will need to fill each piece.
Bronze
Next we weigh the bronze needed and heat it in the furnace.
As the bronze heats up the shells are put back in the kiln to preheat.
Reheating shells
While everything heats up we get metal buckets or empty file cabinets drawers (as were used the night this was filmed) and fill them about 1/3 full with sand.
Buckets of sand that will hold the shells when we pour in the bronze.
Additional buckets of sand are set aside to pour around the shells.
Buckets of sand ready to be poured around the shells.
Bullion molds are heated for the excess bronze.
Molds for excess bronze
We all put on our leather safety clothing, gloves and helmets with screens to protect our faces should the bronze spray or squirt in our direction.
Safety apparel
When it is time to pour David with special gloves on picks up each shell and places it in one of the buckets. I with a pair of thick welding gloves and an additional pair of fire proof gloves cover the opening of the shells and hold them up while others pour sand around the pieces. The sand not only helps hold the pieces up but helps hold the heat in. Covering the opening keeps the sand from getting in the shell. Once all the shells are set up Will and Carlos lift the crucible out of the furnace with (80 lbs. in this pour) the molten bronze and set it in the fulcrum and ring. They then clean out any debris floating on top. Next they each grab and end of the fulcrum and lift the ring holding the crucible of bronze. The one that gets the pour end of the fulcrum is known as the dead man. I then remove the covers of the first shell. They pour bronze into the piece until the cup and vents remain full. I then replace the cover. We always have someone who watches for leaks, if there is a leak they quickly stick a lump of sparset on the leak. The excess bronze is poured into the bullion molds to be used in the next pour. Will and Carlos then lift the crucible back in the furnace and we all cheer.