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Oct. 29, 2001
Nov. 7, 2001
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Dec. 18, 2001
Jan. 29, 2002
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May 29, 2002
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May 1, 2003
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Apr. 3, 2002 Apr. 12, 2002
Erection of the statue begins at Robinson Iron on the specially constructed steel support platform. Vulcan will be erected all the way to the head so that the left arm can be properly configured in relation to the anvil location. Roger Howard fabricates the stainless steel armature which will be placed inside the statue for support and anchorage to the top of the stone pedastal. Master patternmaker Al Ballint prepares a wood form to replace Vulcan's missing hammer. Al uses a full size layout of the hammer to check his work. Patternwork has begun on Vulcan's new spear. This is the head of the spear which will be 3'2" wide by 4'4' long.
Apr. 12, 2002 Apr. 23, 2002
A new flange is being made for the left forearm at the point of attachment to Vulcan's left hand. The wood pattern will be used to make a sand mold for the iron casting process.
Repairs to the flange on the right forearm near completion. The repaired flange will provide a more secure connection between the right forearm and the right arm. Al Ballint completes one half of the new hammer pattern. He is using white pine for the pattern which will be used by the foundry to make a casting which will look exactly like the pattern. A computer controlled cutting machine is being used to cut two 1 3\4 inch thick stainless steel plates for the bottom of Vulcan's feet. These plates will be used to re-anchor the statue to the pedestal.
Apr. 23, 2002 May. 2, 2002
A finished plate awaits placement under Vulcan's foot. These plates will provide the needed support for the new armature under construction for the interior of the statue. Cast iron is tapped from a 40 ton induction furnace. The pouring temperature is 2700 degrees fahrenheit. The cast iron is poured into a sand mold. The mold contains a hollow impression of Vulcan's new speartip. After pouring the casting will cool for an hour before it is removed from the mold. The red hot spear tip casting appears after the top half of the sand mold is removed. The casting appears to be sound.
May. 2, 2002 May. 29, 2002
The speartip casting is ready for fabrication. Another half casting will be made using the same pattern. The two halves will be welded together then attached to the square shaft to form the complete spear. The pattern for Vulcan's new hammer handle nears completion. The carved shape is based on close up analysis of the 1904 Library of Congress photographs. These custom cut one inch thick stainless steel plates will be used at each casting joint in the torso. When the castings are hoisted on Red Mountain the armature will already be inside each casting. The main support columns are being inserted into the legs by a crew of Robinson riggers. These columns are built of two inch thick stainless and weigh 5000 pounds each.