Two molds are required to make our brass door knocker, one for the body and one for the clapper. We will only describe the making of the body portion from here on as both molds are made the same way.
The mold we use in foundry terms is called a flask. The top portion is called the cope and the bottom section is called the drag.
The pattern is carefully placed into the cope with the runner and gates.
The cope containing the pattern is packed tightly with the green sand and turned over.
The drag is placed on the cope and also packed tightly with green sand.
The flask is opened and removed leaving the completed mold ready to take to the pouring area where we will make the casting for our brass door knocker.