Basics of Metal Casting

This 14 hour session will introduce the student ito the basics of casting two metals - BRONZE and PEWTER.

Saturday will start with the ancient method of casting pewter in soapstone moulds. Each participant will cut their own mould block (which they get to keep) using simple hand tools. After lunch, several pours will be made using a modern lead free (92 % tin) pewter alloy. These will be finished into completed pendants as time permits. The day will be finished up with an introduction to carving waxes for small bonze objects. (Students may borrow tools for the evening to work ahead on their master pattern.

Starting on Sunday, we will learn how to cast bronze using green sand moulds. Each will pack several boxes around their completed patterns. A first pour will be done (before lunch) using pewter as a test. After lunch fresh moulds will be made, and several pours will be made with liquid bronze.

This program does not require any previous metalworking experience. Session limited to four students. Course fee of $300 (+ HST) includes coffee and all materials.

Bronze Casting in Green Sand: An overview of the method.
	Packing the sand around the pattern	Carefully removing the master pattern
Packed sand with pattern removed	Sand mold ready for pour	Carefully heating the bronze
Quickly pouring the molten bronze	Bronze solidified in the mold	Opening the mold
		Images by * * Taken at the 2008 'Earth, Air, Celtic Festival in Goderich ON.
Cleaning off the carbonized sand	Raw casting beside master pattern

Pewter Casting in Soapstone: Molds, castings and finished pendants.

Your instructor is professional blacksmith Darrell Markewitz of the Wareham Forge. Please look over Darrell's past work with Pewter Casting and Historic Reproductions.

Each student should come with some ideas for a posible small object, roughly pendant sized. Handouts are included, but a notebook may prove useful. All tools and safety equipment are provided, the course fee includes the materials to produce a number of finished pieces in both pewter and bronze. Students should dress for the workshop - long pants and work suitable shoes or boots required.

The shop combines traditional and modern equipment, with the main forge coal fired (for forge welding) and two gas forges for general forging steps. There will be one anvil per student, all basic tools will be provided. A 50 lb throw air hammer will be used for drawing out. Equipment includes the related grinding and polishing machinery, as well as a fully equipped fine metals studio.

The Wareham Forge is located in Grey County (Central Ontario), about half way between Orangeville and Owen Sound. We are about 5 miles SE of the village of Flesherton, just off highway 10, (about 2 hours drive NW of Toronto).

Course Fee: $300.oo (plus 13% HST) Includes all materials Includes one 4 x 1 x 1/4 pattern welded billet All necessary tools and safety gear is provided

Book your course  via the electronic payment system. ENSURE YOUR COURSE REGISTRATION! I will respond via e-mail with further instructions. $100.00 CDN DEPOSIT on 'Basics of Metal Casting' Course fees and deposits can be made with your credit card. Contact me for further details

courses@warehamforge.ca

Can't make it to Wareham?

Take a look at the educational DVD's / CD-ROMs produced by the Wareham Forge

Introduction to BLACKSMITHING	Historic BLADESMITHING	Forging the VIKING AGE	IRON SMELTING in the Viking Age	Exploring the Viking Age in Denmark