Behrends Bronze in Edmonton is a great company that produces mostly custom signage, much of it in metal, some of it cast in bronze and aluminum. I did sculptural work for them for a couple of decades. I never met the owners or management in person, but they were always great to deal with.
Still, here's a job that landed in my 'hall of shame' folder.
Still, here's a job that landed in my 'hall of shame' folder.
It was to look like this, about 2M, 6 feet high, in relief. The name 'Evanston' came along as the name of the job. Until today, I had no idea what this was for.
I was feeling pretty confident. I cut out the letters, a 3D trick involving layering thin plywood over thicker ply, joining the pieces with little brads. I would cut out and sand the shape of the letter outline to some accuracy. Then I'd separate the two parts, cutting the thicker ply to make a thin wall that made a hollow letter, just right for casting. Most metal casting is done as thin as possible to save metal, reduce weight, and made the process easier.
I drew the outline of the wheat onto a big board on the floor, opened a big bag of potter's clay, and got to work. I modelled this in record time, patting myself on the back for being so darned clever: I'd made a press mould for the wheat heads, so that doing the entire array was a matter of pushing the soft clay into the mould, banging it out, and pushing it into place. Man, I felt like some kind of professional.
I was feeling pretty confident. I cut out the letters, a 3D trick involving layering thin plywood over thicker ply, joining the pieces with little brads. I would cut out and sand the shape of the letter outline to some accuracy. Then I'd separate the two parts, cutting the thicker ply to make a thin wall that made a hollow letter, just right for casting. Most metal casting is done as thin as possible to save metal, reduce weight, and made the process easier.
I drew the outline of the wheat onto a big board on the floor, opened a big bag of potter's clay, and got to work. I modelled this in record time, patting myself on the back for being so darned clever: I'd made a press mould for the wheat heads, so that doing the entire array was a matter of pushing the soft clay into the mould, banging it out, and pushing it into place. Man, I felt like some kind of professional.
The finished clay master with wood letters in place. My plan was to do some smoothing in the mould, where smoothing the lines and surfaces is pretty easy.
So I covered the whole thing in plaster. Then I added more. There's nothing more frustrating than having a mould break, as the master is usually done at that point.
I added more plaster to be sure, then tied in long steel pipes for more strength. I was being professional, careful.
Next day I tried to lift this. I had to roll it over, right? Huh. It must have weighed 350 pounds. I had to buy a 'come-along'' a winch thing for stretching fencing, fasten it to the ceiling, and slowly winch this mould over. This took me all day.
I don't remember how long the smoothing part took. Awhile. There is this local saying: "I'll be home soon, honey" that is a bit of a joke.
And, of course, this mould had to be filled with a reasonably even 3/8" of epoxy-fibreglass. Sigh, that's a lot of goo to mix and smooth in. A lot of fairing afterwards. I'm not going to look at my old records to see what I got paid for this. I try to avoid pain and embarrassment.
And then, just tonight, I stumble on this photo:
I added more plaster to be sure, then tied in long steel pipes for more strength. I was being professional, careful.
Next day I tried to lift this. I had to roll it over, right? Huh. It must have weighed 350 pounds. I had to buy a 'come-along'' a winch thing for stretching fencing, fasten it to the ceiling, and slowly winch this mould over. This took me all day.
I don't remember how long the smoothing part took. Awhile. There is this local saying: "I'll be home soon, honey" that is a bit of a joke.
And, of course, this mould had to be filled with a reasonably even 3/8" of epoxy-fibreglass. Sigh, that's a lot of goo to mix and smooth in. A lot of fairing afterwards. I'm not going to look at my old records to see what I got paid for this. I try to avoid pain and embarrassment.
And then, just tonight, I stumble on this photo:
Huh. This turned out pretty well! Maybe money isn't everything. In hindsight. When it turns out we didn't starve after all. When it turns out we had good food, good friends, a sweet place to live and interesting work.
I'd been in business 33 years when I did this job. Just how long does it take to find wisdom? Or, yikes, mastery?
I'd been in business 33 years when I did this job. Just how long does it take to find wisdom? Or, yikes, mastery?
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