We receive your wax and add a post and loop (those are the doohickies that make it attach to your belt strap), then gate it and attach it to a tree with other buckles.
Step Two: The Shell
When the tree is ready, we cover it in a ceramic shell. The dipping process to cover the wax in shell takes about a week and involves dipping the wax in a big slurry tank, sprinkling it with sand and letting it dry five times.
Step Three: Melt out the wax
Now that we've built up a shell we've created the mold that the bronze will fill. But before we add the bronze we need to melt out the wax. That's why it's called the lost wax process. Get it?
Step Four: Molten Bronze!
After the wax is gone, we need to heat up the shell so that it can accept 2,100ºF bronze without disintigrating. When the shell is hot, and the bronze is melted, we pour the bronze into the shell.
Step Five: Break it out and cut it off
When the bronze has cooled, we knock off the shell and cut the buckles off the tree.
Step Six: Chase and Patina
We use a grinder to clean up the spot where the tree was connected to the buckle and give it a light patina to bring out the rich color of the bronze.
From wax to fire
The casting process we use for every Metalcast Kits Buckle