The process of casting a bell, as employed both by ancient and modern
founders, may be described somewhat as follows:--The first business is
the construction of the core, a hollow cone of brick somewhat smaller
than the inner diameter of the intended bell, over which is plastered a
specially-prepared mixture of clay, bringing it up to the exact size
and shape of the interior of the bell. This was usually modelled with
the aid of a wooden “crook,” something like a pair of compasses; but
is now done with an iron framework called a “sweep,” which revolves on
a pivot and moulds the core by means of metal blades. This clay mould
is then baked hard by means of a fire lighted within it. The next
stage was the construction of the cope or outer casing of the mould,
which used to be also made in hard clay, its inner surface following
the _outer_ shape and dimensions of the bell. The “thickness” of the
bell itself, i.e., the part to be occupied by the molten metal, was
formed in a friable composition which was laid over the core and then
destroyed. In modern times the “thickness” has been dispensed with,
the cope being formed by lining a casing of cast iron with clay shaped
to the external form and dimensions of the bell. The mould is now
complete, except for providing for the cannons or metal loops which
attach the bell to the stock, and the loop to which the clapper is
suspended inside. Every care having been taken to adjust the respective
positions of the cope and core with exactness, the molten metal is
then poured in through an opening, and left to cool, after which the
bell comes out complete. The process is analogous to that known as
_cire perdu_, employed by sculptors for the casting of bronze statues.
Illustrations of the moulding processes are given in Plates 6-10.
Inscriptions and ornaments are produced in relief on the bell from
stamps, also in relief, which are pressed into the mould, making a
hollow impression in it. Copies of coins were often produced in this
way by the older founders. Down to about the end of the seventeenth
century each letter, or sometimes each word, was placed on a separate
_patera_ or tablet of metal. The usual place for the inscription is
just below the “shoulder”-angle; but modern founders prefer the middle
or “waist.”
[Illustration: _Plate 4._
THE BLESSING OF TWO BELLS NEWLY HUNG IN A CHURCH TOWER.
From a MS. Pontifical of the fifteenth century. (See page 6.)]
Public-domain text, read in full here on John Shaqi.
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