Step 1: If desired, sketch out your design to determine how many BRONZclay™ beads you will need to make.
Step 2: Creating the molds:
Select the rocks you will be using to make your molds. Rinse them with water to remove any dust or debris. Since you will also be using these rocks to make molds, make sure the rocks are relatively smooth and free of undercuts or major defects; this will ensure clean molds.
Step 3: Take the rock to be molded and use a permanent marker to mark a line around the circumference of it. This line will help you determine how deep the rock should be pressed into the mixed mold compound.
Step 4: Take equal parts of the two-part compound (each part should be about the size of the rock you are molding).
Note: Once the Rio Cold Mold compound parts are mixed, the curing process begins immediately and you’ll have only a few minutes of working time, so make sure you have everything ready before you begin mixing.
Step 5: Mix the parts together until the color is uniform. Roll and form the compound into the approximate shape of the rock. Note: The form must be taller than the rock being molded.
Step 6: Lightly press the rock into the compound up to the circumference line; be careful to not press all the way through the compound. If necessary, tap the mold compound around the circumference of the rock so it makes contact with all sides. Make sure the mold compound is level around the rock. Allow to cure for approximately 15 minutes (or as directed by the manufacturer). To test if the compound has cured completely, lightly press your nail into the rubber. If it leaves a mark, then it has not completely cured; the mold will feel firm yet slightly rubbery once completely cured.
Once the compound has cured, remove the rock and inspect the mold to make sure there are no air bubbles or other imperfections. Insert the rock back into the mold.
Step 7: Mix another batch of mold compound at the same ratio as in Step 4 and roll it into a ball. Press the center of the ball down onto the center of the rock and form the compound down and around the rock so it’s completely covered. Gently press the edges in toward the rock. Allow to cure for approximately 15 minutes; then perform the curing test in Step 6.
Step 8: Once the mold has completely cured, pull the top and bottom halves apart; if necessary, use the craft knife from your tool kit to pry them apart.
Step 9: You now have a two-part mold and are ready to make your BRONZclay™ beads.
Step 10: You will need slip when making the BRONZclay beads. Make your slip ahead of time; here's how!
Mix tiny pieces of clay (filings, small fresh or dried pieces, etc.) with water (we recommend distilled water) until you reach a toothpaste consistency. Keep your slip stored in a sealed container; stir before using. Note: Slip lasts for about one week, so make only enough for your immediate need.
Step 11: Roll your BRONZclay™ three-cards thick.
Step 12: Place the rolled BRONZclay™ into one of the mold pieces. Use your fingertip or knuckle to gently tap it into place, making sure all the BRONZclay is making contact with the mold. Use the craft knife to trim excess BRONZclay from the edges of the mold.
Repeat with the other half of the mold. Set aside the two molds and allow the BRONZclay to dry. To hasten drying, use a food dehydrator.
Step 13: Once dry, remove the BRONZclay from the molds.
Step 14: Use a sanding pad or nail file to sand the edges of both domes flat. As you’re filing, periodically place the domes together to make sure the edges match.
Step 15: Dip the paint brush in water and run it along the sanded edge of each dome.
Step 16: Use the paintbrush or blending tool to pick up slip; run a line of slip along the edge of one of the domes.
Step 17: Press the two domes together, forming a saucer bead; hold the pieces together for about 30 seconds. Use the blending tool from the tool kit to blend any slip that comes out at the seam.
Step 18: Set the bead aside and allow it to dry. Once dry, if there are any gaps in the seam, use more slip to fill them; use the blending tool to smooth until the seam is no longer visible. Allow the seam to dry.
Step 19: Use a sanding pad or nail file to sand the edges of the seam smooth.
Step 20: Use a pencil to mark where you would like to place the holes in the beads. Using the 1.5mm twist drill, gently drill a hole through both sides. Note: Remember to let the drill do the work; if you use too much pressure on the drill,
the bead may crack. If the holes are at the seam, the seam may open slightly. If this occurs, simply wet the crack with water and fill with slip. Allow to dry completely.
Repeat Steps 11–20 with all BRONZclay™ beads.
Step 21: Fill the firing pan with activated carbon. Embed the dried beads on their sides in the carbon (placing them on their sides will keep them from collapsing during firing). Cover the beads with a layer of carbon.
Step 22: Firing:
Fire using a slow ramp of 250°F, hold at 1550°F for 3 hours. Allow the kiln to cool completely before removing the firing container from the chamber.
Step 23: Remove the beads from the carbon and rinse with water. Sometimes granules of carbon can get stuck inside the bead hole. Take a pick or awl to remove the carbon from the hole.
Step 24: Use the 400-grit polishing paper over the surface of the beads. This will brighten the surface and give the bronze a satin finish.
Step 25: Drilling the stones:
Place a 1mm drill bit into the drill press. Keeping the rock and drill bit wet, slowly drill a hole all the way through the rock to create a bead. The key to drilling into stone is to use a slow and steady pace while keeping the drill bit lubricated. Here we used water to keep the tips cool. Depending on the thickness of the rock and the type being drilled you may need multiple drill bits.
Step 26: Stringing the beads:
Cut 20" of Beadalon wire. Pass one end through a crimp bead, the round bronze ring and back through the crimp bead. Use the crimping pliers to secure the crimp bead in place. Use the shears to clip off any excess wire.
Step 27: Add beads in this order: 4mm, 6mm, 4mm, and then the bronze spacer bead. Repeat this pattern four more times, leaving the spacer bead off of the last section.
Step 28: Add the BRONZclay™ and drilled stone beads, separating them with one 4mm jade bead. Once the last BRONZclay bead has been added, repeat Step 27.
Step 29: Pass the Beadalon wire through a crimp bead and the ring on the Dexterity clasp. Pass the wire back through the crimp bead and close using the crimping pliers. Clip off any excess wire.
Your "Seattle Surf" necklace is complete!
