The images above show how I went about creating the moulds for each individual panel on the former. This process was repeated for each of the 16 panels and each mould took between 8 and 10 hours. I first constructed a segmented wooden frame to fit onto my former and held it in place with screws; then I put cardboard around the edges. Kiln dried sand is mixed with Sodium silicate and then placed into the frame, ramming the sand between layers ensures a tightly packed sand mould. Using a steel spike, holes are pushed into the sand to allow CO2 gas to be pumped in, this reacts with the sodium silicate and hardens the sand. The section of the mould is removed from the former and a packing material (foam etc) is placed onto the surface. Keys are cut into the sand and the ramming and gassing process is repeated for the second half of the mould. The mould is opened and the packing material is removed, this leaves a cavity within the sand to receive metal later. The running system is carved into the sand and the face surface of the mould is treated with a mould wash that is set alight to harden and remove moisture. The 2 halves of the mould are glued together and strapped using metal banding.