Escape Ibn Navarrone-D

Life-Size Portrait Bronze
Unveiled January, 2009 at Ajman Stud

Commissioned by Sheikh Ammar bin Humaid Al Nuaimi

Ajman Stud, United Arab Emirates

Exclusive Edition of Two Life-Size bronzes

Life-Size Bronze
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

www.treesmedia.com

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.

Bronze Ingots

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

Trivia about the production of the Escape Life-Size Bronze 
Length of horse:  9 feet
Height from base to top of horse head: 7 ft  6 inches 
Height of withers of horse: 15.3 hands 
 
Weight:  1300# total weight 
    The Life-size bronze horse 900#  
    400# of stainless steel structure is inside the horse and base 
 
Crate and Bronze weight:   2323.67 # 
   
150"  (381 cm) long x 48" (121.92 cm) wide x 100" (254 cm) high
 Total time: Approximately a year and a half!