Step 1: Your kiln should be preheated to 1425°F; we recommend turning on your kiln at the beginning of the day so it’s already heated when you begin to enamel.
Step 2: Start by drawing your design onto a piece of paper. Cut the cloisonné wire into pieces and begin to shape them by hand according to your design. Use tweezers to place the strips on top of your drawing. If further shaping is required to match your design, shape by hand or use pliers, especially for sharper bends. Set the wires aside.
Step 3: To clean the disc base, heat it with a torch or in the kiln for a couple of minutes, then allow it to cool. Once the disc is clean, hold it only along the edges to avoid leaving fingerprints on the surfaces.
Step 4: Now it's time to counter enamel. Applying a layer of counter enamel to the back of the disc helps equalize the expansion and contraction of the metal, preventing the enamel that will eventually be applied to the front of the disc from cracking. Use any color you like for the counter enamel (for this project, we chose blue to complement the design we will apply to the front). NOTE: “Cool” colors such as blue or green are more stable through multiple firings.
Step 5: Place a piece of paper on your work surface to catch sifted enamel powders so that you can later replace them in their jars. Make sure to keep each enamel color separate. Wear the respirator for the duration of the project to protect against the fine enamel dust. Fill the sifter half-way full with enamel.
Step 6: Holding the disc along the edges with your fingers, sift a layer of enamel onto the back of the disc. Start along the edges, then work toward the center.
Step 7: Sift a layer that is about 3/4 the thickness of what the front enamel layer will be. Run your fingertip along the edge of the disc to remove any excess powder.
Step 8: Carefully set the disc on the three-slant firing trivet, being careful to not disturb the enamel powder, then place the trivet on the firing rack. Wearing the safety glove, use the firing fork to place the rack into the center of the kiln. Fire the counter enamel for approximately 2-1/2 minutes. Please Note: The firing time may vary according to the kiln you’re using. Fold the piece of catch-paper and pour the unused powder back into its jar.
Step 9: After 2-1/2 minutes, put on your safety gloves and remove the firing rack using the fork. Set it aside to cool. The surface of the counter enamel will resemble one of the following textures:
• sugar (crystallized specks)
• orange peel (dotted impressions)
• fully fused (smooth and glossy . . . exactly what we want!)
If the surface exhibits a "sugar" or "orange peel" texture, allow the piece to cool, then fire again for approximately 2-1/2 minutes. If the enamel layer is somewhat thin, you can sift on another layer, and then fire. Repeat this process until the surface of the enamel is fully fused. Please Note: It takes slightly less time to fire enamel onto enamel (rather than onto metal); if you add additional layers during this process, firing time may be slightly less.
Step 10: Clear flux serves as a barrier between the base metal and the enamel, allowing the true color of the enamel to come through after firing. Clear flux will also help hold the cloisonné wire in place. Sift a layer of clear flux onto the front of the disc using the same technique you used for applying the counter enamel). Fire it for 2 min., 45 sec. If the surface exhibits the “sugar” or “orange peel” texture, sift on another layer of flux and fire again for approximately 2-1/2 minutes. Once the enamel has completely cured, the surface will be fully fused.
Step 11: Pour some Rio enamel adhesive into a small bowl. Use the tweezers to dip one edge of each cloisoneé wire into the adhesive.
Step 12: Place the wire onto the fluxed side of the disc according to your design. Once all the wires are in place, allow the adhesive to dry completely. Place the disc back on the trivet and fire for approximately 2-1/2 minutes. Remove the disc and allow it to cool.
Step 13: Now it's time for some color! You will be using the wet-packing method to apply color enamels to your piece. NOTE: We recommend applying “cool” colors first because they are stable enough to handle multiple firings. You can either fire after each color application or, to speed up the process, you can fire several colors simultaneously.
Begin by scooping a small amount of the first color into a gem jar (blue for our project). Use a dropper or cocktail straw to add water to the powder, then stir with a needle tool. The consistency should be just thin enough to pick up the solution with the brush you will be using to apply the enamel.
Step 14: Pick up some of the wet enamel with a sable artist's brush or needle tool and apply it into the cloisons, or "cells." Fill each cell higher at the edges than in the middle. For areas that don't have a wire border, make sure there's enough enamel so that the color won't round off to nothing during firing.
Step 15: TIP: Use a paper towel to carefully wick away excess water from the edges of the cells.
Step 16: Thoroughly clean the brush in a cup of water, then apply the next enamel color (green for our project); repeat, then apply the black enamel. Set the piece on the trivet, on top of the firing rack, and set the rack on top of the kiln to speed up drying. Once the enamel is dry, fire it for approximately 2-1/2 minutes.
Step 17: Remove the piece from the kiln and allow it to cool. Apply the remaining enamel colors (red and white for our project) as described in Steps 14 and 15, then allow them to dry. Fire the piece for approximately 2-1/2 minutes, then remove it and cool for 3–5 minutes. Please Note: "Warm" colors may require slightly less firing time.
Step 18: Once the piece has completely cooled, use cutters to trim off excess cloisonné wire.
Step 19: Use the alundum stone under running water to stone down the front of your piece. Rub the piece in different directions to avoid creating any low spots in the enamel. Keep checking the surface of the piece with your fingers, continuing to stone down rough edges from the wire.
Step 20: Clean the enameled surface with a glass brush, then flash-fire the piece for 45–60 seconds, or until the surface becomes glossy. Use the E-6000 to attach your piece to the glue-on pendant bail in the kit, then string onto the rubber cord to finish! Your enameled pendant is now complete!
