Escape Ibn Navarrone-D
Escape Ibn Navarrone-D
Unveiled January, 2009 at Ajman Stud
Commissioned by Sheikh Ammar bin Humaid Al Nuaimi
Ajman Stud, United Arab Emirates��
Reference Photo with permission from Scott Trees
Original 1/5 Life-Size clay model
6 months to sculpt
Judy and Kim work from the photos and measurements of Escape to create the 1/5 Life-Size sculpture in clay.
Finished 1/5 Life-Size Bronze
Foundry time 3 months to cast
Foam enlargement process -- 4 weeks
A mold is made of the 1/5 Life-Size clay model. A wax is poured and cut into sections. A laser scans each section which is enlarged with a CAD program. Then the blue foam model is milled into sections. The blue foam sections are glued together in preparation for the artist to add the clay.
Sculpting Life-Size clay -- 4-5 months
It takes days of carving into the foam to redefine the detail of the foam model. Then months of adding the clay to the foam model to sculpt the details of the muscles, tendons, and facial features.
Finished clay of the Life-Size Escape ready for the mold process.
Mold making -- 8 weeks
The clay sculpture is cut into 40 different sections for molding. Rubber is painted on the clay sculpture and then coated with plaster of Paris for support.
Foundry process to cast bronze -- 8-10 weeks
Plaster of Paris molds
Pouring wax into the Plaster of Paris molds
Cleaning seam lines of the waxes
Dipping the waxes into the ceramic shell mixture.
Drying the ceramic shells
Lost Wax Process - Ceramic shells are put into the kiln to melt out the wax. This also preheats the ceramic shell before the molten bronze is poured in to prevent the ceramic shell from cracking from the extreme temperature.
Gas fired crucible heats the bronze ingots to 2000 degrees
Pouring the molten bronze into the ceramic shells
Breaking the ceramic shell away from the cold bronze
51 bronze metal panels and parts are now now welded together.
400# of Stainless steel were welded inside the bronze legs and barrel for structural support.
Grinding the weld lines of the bronze to recreate the texture of the original clay sculpture
Bronze Patina -- 1 week
The bronze is sand blasted to prepare the surface for the patina. Specific chemicals are used to obtain the variation in coloring on the finished bronze. The chemicals are sprayed on at the same time the bronze is heated with a propane torch to heat the metal to the proper temperature
Building the crate for shipment to Sheikh Ammar in Ajman, U.A.E