By FRED MILLER III
First, the bronzes take shape as modeled clay. Lillegard adds, peels and scrapes
until the shape resembles what he sees in his mind's eye. Next, a silicone
rubber shell is pasted around the clay, preserving delicate intricacies.
A plaster shell is then added for strength, then Lillegard splits the shell
open and removes the clay. After re-joining the plaster and rubber, he
fills the mold with molten wax. When the wax hardens, he peels away the
rubber. The wax replica of the clay sculpture is then dipped in eight layers
of a ceramic slurry.
This ceramic shell is placed in an insulated kiln, where forced gas is
ignited and the temperature is raised to 1,600 degrees. At that point, the
wax vaporizes.
With help from his uncle, Glenn Lillegard, bronze is poured into the ceramic
shell to replace the wax. When the bronze cools, Glenn removes the ceramic,
first with a hammer and chisel, then with a sandblaster. Then, Steve uses a welder and pneumatic grinders to join parts and to touch up blemishes. Finally, chemicals are applied which bring out the bronze's contrasting colors.
The sculpture is then attached to the custom-designed and polished black
walnut base. A signature plaque is set on the front of the base, and the
bronze is ready to go.
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