Life-Size Bronze Portrait
Commissioned by Royal Court Affairs
Oman Royal Cavalry
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.
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.
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.