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BACK
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Casting
a japanese kettle
Copied from http://www.jgc.co.jp/waza/b6_jmetal/index.htm
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single product method starts with the making of the casting mold. First of all
the mold for a pot or iron kettle, without a pattern, is made by the caster's
hands. |
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Next the design is pressed. A consecutive pattern of small circular protrusions
called "Arare" (hailstones) is generally used. Before the body mold dries, a
sharp brass gimlet is painstakingly pressed to form the pattern. In moving toward
the upper part of the body, the hailstones become smaller in size.
Besides "hailstones," there may be representations of flowers and birds, animals
or natural scenes. Thin paper on which a rough sketch has been drawn is turned
over and pasted on the body mold and carved with a spatula. This is work requiring
great experience.
This is monotonous work is carried out while closely observing the entire condition
but it is work accompanied by continuous tension. The appearance of the product
is determined by the angle, form, depth of the "hailstones" and the space between
them. |
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Pressing the pattern |
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 Arabiki: making the outer casting
mold |
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Making Nakago (inner mold)
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| After
the circular mold for the handle is attached and the body condition adjusted,
the inner mold is prepared. In casting, the space between this inner mold and
the outer mold becomes the thickness of the pot. |
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Assembling casting molds.
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Fitting
together the outer mold and inner mold (core). |
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Casting
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| After
the casting mold is thoroughly dried, the casting begins. The moment the molten
metal is poured into the mold is one when even a veteran metalworker feels like
praying fervently for success. |
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Removing the cast 
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When
the cast metal hardens, the body mold is removed and the inner mold crushed
with a metal rod. |
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Heating
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casting is heated with charcoal fire at high temperature for two or three hours
to form an oxidized integument of magnetic oxide of iron on the surface. This
not only settles the iron body but is also processing for rust prevention. |
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The
final step is coloring. After a lacquer undercoating, the heated iron is placed
in Sake (rice wine) and then a special paint called "Ohaguro" fermented for
several months is spread over the now slightly heated surface of the pot. The
surface of the pot gradually changes into a quiet darkish color. This is the
craftsman's final affectionate farewell to his product. |
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Coloring
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Living room of a private house in a local district. In the center is
the "irori," a sunken hearth made by cutting out a square piece of the floor.
A Nambu kettle is an indispensable item here.
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