It was a good idea to make the prototype as I am working out any issues on this piece before I introduce that method to the Final Four pieces.
I discovered that the making of the head is a very time consuming job, about 12 hours work; there must be a better way.
This led me to a foundry here in Bendigo, Keech Castings, and they are letting me help with the process of making the moulds and then pouring molten steel in to form the heads.
This is the pattern I have made with which we will make the moulds to cast the steel next week.
Molten steel being poured in to moulds.
The steel is heated by electricity and takes about 4 hours to melt the steel in this big bucket. I would really not like their electricity bill!!