Zoumir

Life-Size Bronze Portrait

Commissioned by Royal Court Affairs
Oman Royal Cavalry

His Majesty
Sultan Qaboos bin Said
Sultanate of Oman

Exclusive Collector's Limited Edition of One

Zoumir
Zoumir


Life-Size Bronze Portrait

Commissioned by Royal Court Affairs
Oman Royal Cavalry

His Majesty
Sultan Qaboos bin Said
Sultanate of Oman

Exclusive Collector's Limited Edition of One

Original 1/5 life-size clay model 2 months to sculpt.

Judy and Kim work from the photos of Zoumir to create the 1/5 Life-Size sculpture in clay.

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 -- 10-12 weeks

The Life-Size Foam Sculpture is shown with the wax of the 1/5 Life-size model wax to show the scale difference.

It takes days of carving into the foam to redefine the detail of the foam model. Then we add the clay to the foam model to sculpt the details of the muscles, tendons, and facial features.

Finished clay of the Life-Size Oman Race Horse ready for the mold process

Mold making -- 4 weeks

The clay sculpture is cut into sections for molding. Rubber is painted on the clay sculpture and then coated with plaster of paris for support.

Foundry process to cast bronze -- 4 weeks

Pouring wax into 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

Bronze metal sections

Assembly of the bronze

400# of Stainless steel were welded inside the bronze legs and barrel for structural support.

Welding the metal

Grinding the weld lines of the bronze to recreate the texture

A stainless steel rod was inserted through the horse to support the jockey. The jockey was welded to the horse and the stainless steel support.

Brigadier General Abdulrazak Alshahwarzi, Commander, Royal cavalry Oman came for the final inspection! Shown here with Judy and Kim.


Bronze Patina -- 2 days

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

Some interesting facts about the Oman Life-Size Race Horse:

Length of horse: 11 ft x 7 inches long (353.06 cm) 
Height to top of Jockey: 7 ft 3 inches (220.98 cm) 
Height of withers of horse: 15.3 hands (160.02 cm)

Weight: 1410# total weight (639.565 k) 
The Life-size bronze horse and jockey weighed 1010# (458.128 k) 
400# of stainless steel structure is inside the horse and base (181.4 k )

Crate and Bronze weight: 2323.67 # (1054 k) 
150" (381 cm) long x 48" (121.92 cm) wide x 100" (254 cm) high

Total time: Approximately 8 months

NOTE: All of the times below were on a rush schedule as we started late. It usually takes one year for a life-Size bronze from the 1/5 Life-size scale model to the finished Life-size bronze.