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CASTING INSTRUCTIONS
SHENA, SHELBY, HELPER AND MUNCHKIN MUGS
Supplies:
J902 Shena Mug mold
J901 Shelby Mug mold
J903 Helper Mug mold
J900 Munchkin Mug mold
KTCAST Casting Kit:
Stirring stick
Strainer
Synthetic Sponge
Greenware Duster
Featherknife
Mold Cleaning Tool
Slip Thinner
Firing Separator
Round Taklon Brush
2 KwikClean Brushes
Casting Instructions
SKIT Stoneware and Porcelain Cleaning Kit
KTBRGC GreenClean Brush Kit
SBR45 Mini GreenCleen Brush
GGL150 Gloss Clear Glaze
Lady White Porcelain Slip
Water in a spray bottle
1. Thoroughly mix Lady White porcelain slip with the stirring stick in the Casting Kit. Strain slip to remove any lumps. If the slip seems too thick, thin it with Slip Thinner according to directions on the label. Let slip sit for about 30 minutes to allow air bubbles to rise to the top.
2. Open the mold and use a permanent marker to number the 3 mold pieces in the order they will be removed after the casting has set up. The bottom piece will be numbered 1, the back piece 2 and the piece that forms the face will be 3. Dust the mold cavity with a Greenware Duster.
3. The handle of the mug has a tendency to stick when you try to remove the casting. To prevent this mist the handle areas in both sides of the mold with water from a spray bottle. You could also use a Synthetic Sponge to dampen the handle area with water.
4. Cast the mug in Lady White porcelain slip, pouring slip in a smooth, steady stream. Fill the mold to about 1" above the rim of the mug. Add some slip if the level of the slip gets close to the rim of the mug. The mug casting should be about 3/16" thick, but no more than 1/4". To check the thickness of the casting, tilt the mold slightly and insert the tip of the Mold Cleaning Tool into the clay wall about 1/2" above the rim of the mug.
5. When the casting has reached the desired thickness, empty slip from the mold back into the jug. After emptying the mold it is very important to rest it on its side with the outside edge of the handle facing down. As the mold finishes draining the handle must fill up entirely with slip and become solid. If necessary, add some slip to make the handle solid. A hollow handle will make proper cleaning and sanitizing impossible.
6. When the casting has set up enough for the mold to open, first remove the bottom section. Next carefully remove the back section so that the mug is facing down. Allow the casting to set up for about 30-45 minutes before removing it from the last section. To avoid warping be very careful not to put pressure on the upper rim of the casting.
7. Allow the casting to dry to the leather hard stage before you remove the spare. Use a Featherknife to trim the spare a fraction of an inch above the rim. Use damp KwikClean Brushes to pre-clean the seams and smooth any imperfections.
8. After casting is completely dry soft fire it to cone 018 in preparation for cleaning in the Dust Free Cleaning Technique.
9. Use a very sharp Featherknife to trim the rim and a Comfy Scrub and GreenCleen Brushes to finish smoothing the seams and rim. Be very careful when working around the rim and handle to avoid warping and stress cracks. Do not hold the mug by the rim or the handle during the cleaning process. A Mini GreenCleen Brush is good for cleaning the facial details.
10. Let cleaned soft-fired ware dry completely before applying Gloss Clear Glaze, which is lead free and food safe. If you want to glaze the entire mug use a KwikClean Brush to apply two coats of glaze to the outside. Let the first coat dry before applying the second. Next, fill the mug about half full with glaze. Swirl the glaze around until the inside is completely coated. You also have the option of glazing only the inside of the mug. Use a damp Synthetic Sponge to remove excess glaze. If you glazed only the inside of the mug, clean up any glaze that accumulated or dripped on the outside. If you glazed the entire mug the lower 1/8" of the mug and the bottom must be completely free of glaze to prevent it from sticking to the kiln shelf during bisque firing.
11. Coat kiln shelf with a fine layer of Firing Sand. Set pieces on shelf at least 1” apart. Bisque fire to cone 6 using witness cones 5, 6 and 7 on the shelf. After bisque firing witness cone 5 should be touching the shelf, cone 6 should be bent to a 10 to 11 o'clock position and cone 7 should not be bent at all.
12. Sand any unglazed areas with a #220 Grit Scrubber in preparation for china painting.
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