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1. Lost Wax Process: paperboard is cut to the shape of the gate and used like a canvas as wax is applied with putty knife and brush to create the textural surfaces. Being too large to cast in one piece, each wax gate is cut into 9 pieces for casting.

2. Bronze ingots on deck to enter the furnace.

3. The temperature in checked: the bronze will be ready to pour at a heat of 2000 degrees.

4. The Pour: the crucible glows bright orange as the molten metal is poured by hand into the molds.

5. Welding: after the molds are broken away the cast bronze is cleaned, finished, pieced together like a jig-saw puzzle & welded. Through much finishing work the welded areas are blended into the texture of the gate.

 


6. Designer/ fabricator Jeff Wittman grinds the welds on the pedestrian gate lock housing.

7. The gates and pillars at the Studio during welding fabrication. The 18 cast parts are now two gate panels; these are framed by square tubing bent and welded onto 3 sides around each panel. The bottom will be finished with a fabricated wheel trolley, allowing the gates to roll sideways.

8. After all the welding is complete, the gates are sandblasted in preparation for the patinaing process.

9. Stoller applies a cold patina to the pedestrian gate. The bronze receives multiple layers of patina after which
several coats of wax will be applied for protection from the elements.


 

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