The Process

From the moment an idea for a sculpture is presented, I begin to think about the design. While I may do sketches to capture the idea, I generally begin work directly on a small scale model. This small scale model may go through several revisions before complete. After this "maquette" is finished and approved by the client, it's time to start the large sculpture.

The full size piece begins when an armature is built, generally from black pipe. Polystyrene is added to the pipe and soon it will be carved to be the rough shape of the sculpture. Most of these supplies are purchased from my local Home Depot.

Over the next several months, a few hundred pounds of a synthetic, non-hardening clay will be added and sculpted. The clay will carry the texture and form that will be preserved in bronze and is generally one-half to one inch thick over the polystyrene. Photographs and live models are often used as reference to make the works as realistic as possible.

After the life size clay work is completed, the sculpture is taken to the foundry. Latex molds are made from each section of the sculpture and a wax replica is made before the final casting. Once this is approved, the wax is dipped in about twelve layers of a ceramic shell. When this "slurry" hardens around the wax, the clay is fired and the wax melts out. The hot bronze is poured into the remaining shell through channels built for that purpose. After the bronze has cooled, the separate pieces are joined together. In the final stage, the bronze is given a "patina" or protective coating.