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Casting
slip into the production mould, Page One of Three.
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This
photo shows how ordinary white earthenware plastic clay together
with other dry ingredients is made fluid by the addition of a small
measured proportion of water and two soluble alkalies known as deflocculants.
There
is further information on how to make solid clay flow like cream
on a related page: clay
slip.
In his
book, "Mold Making for Ceramics" (ISBN 0-8019-7359-7)
Donald Frith describes in detail the chemical and practical processes
of making and using clay slip in a manufacturing environment (in
America).
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The void
inside the Shire mould takes approximately six pints of slip. Slip
is nearly twice the weight of water. One pint of slip weighs 35
ounces. Therefore the slip in the mould weighs about 13 pounds.
This weight of slip needs to be kept securely inside the mould otherwise
there would be a mess all over the floor. Instead of strong rubber
bands (cut from lorry tyres) that I use on smaller moulds, here
I have strapped the mould up tight with adjustable luggage straps.
The mould
weighs more than 60 lbs (I am not sure quite how much more as it
is more than all the calibrated weights I have). With the slip inside
it is too heavy for me to lift to pour out the slip that is still
liquid on the inside. I rotate it clockwise so that I can control
the angle. The filling hole which is in the top right corner is
then over an empty bucket beneath the slats of the casting bench.
The slip must pour out at the same rate as air is allowed back inside.
If I did not blow air in through a tube, the suction as the slip
pours out creates a vacuum that can (and often has done) collapse
the soft clay lining thus pulling it away from the plaster mould.
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The next
page shows the mould with the starboard big side removed.
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