I covered one surface with masking tape and, using a protractor and a square, I laid out the design on the block.
Then I cut through the lines into the wax beneath, transferring the design.
Next a put a high-speed burr into the drill press and used it like a milling machine, cutting away wax where I didn't need it and adjusting the height of the table for each layer.
Initially I was going to exactly replicate the source image, but once I saw the curved edges being left by the burr I decided they were more attractive and suited this piece better. After about half an hour and a big pile of wax shavings I had my design.
I used a hacksaw to cut it free from the rest of the block, and milled the back down to flat to hide my poor cut.
|Not such a hot-shot with the hacksaw.|
The last thing I needed to do to the wax was pre-drill holes for the arms of the goggles to be riveted, this isn't mandatory but it's easier to drill the wax than the metal.
Then I cast it in bronze.
After cutting off the sprues and cleaning it looked pretty good.
So I applied a black patina and then buffed it back off, dramatizing the low areas.
Now I have all the bits made, and it's time for assembly.