Intermediate Mould-making, page 3 of 4.

LENHAM POTTERY MODELS
making high-fired semi-porcelain models since 1969

Seven steps to the Shire Horse Model: Step Three

This is
Step Three:
Intermediate
Mould-making

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Back to
Step One:
armature

Step Two:
modelling

Step Four:
making the
rubber model

Step Five:
plaster
production
mouldmaking

Step Six:
slip casting

Step Seven:
fettling and finishing

Back to the
Introduction

Making the Intermediate mould, Page Three of Four.

This shows the starboard big side of the plaster jacket. This section of plaster weighed 24 lbs (wet). It was deliberately made denser than would be normal for a production mould in casting plaster, and began to crystallise before all the plaster was out of the bucket. This is why the surface shows trowelling marks.
I have highlighted the positions of the leg wires in the base-board. The wires remain fixed until the plaster jacket is finished, and then the extra twists on the ends are cut off to free the legs from the board.

Note: nearside and offside refers to cars and horses, but I prefer to use starboard and port as they are more distinctive.

Casting the internal segments of the plaster jacket.

This shows the mould box open with the port side uppermost. I have marked the starboard big side where is shows above the spine and in front of the chest. Four of the internal segments have also been made: Face starboard side (hidden), Face port side, Inner front legs and Outer back legs. Between the outer back and starboard side can be seen the clay wedge which is the filling hole. Clay walls also surround the three parts which will be cast next: the Outer front legs, and the Inner back legs and the small piece above the ears, (marked with red lines). Note that the Inner front legs part is a very strong wedge shape. In practice, I had to make an additional wedge shape, which can be seen in the subsequent pages, to make taking the slip cast model out of the production mould much easier.

The next page is completing the plaster jacket.