How We Make Scrap Metal Sci-Fi

It an take over 200 man-hours to create our most complex statues.  Here is a an explanation of how they are created.

Step 1:  Planning and Design

You might be amazed to know that we rarely sit down to draw sketches or plans when we are desiging a product.  We also rarely create mock-ups.  When we receive a new consignment of scrap metal it is always different and, although some materials will be similar to what we've used before, no two statues can ever be made exactly alike.  Plannig something in advance would only slow down the work and remove the opportunity for our artists to take initativs and to be creative.

We can work from photograph, but where practical we prefer to order resin models from overseas (usually from Japan).  The internet has really helped us to find good examples of these models and we tend to acquire between 3 and 10 models a month.  

We don't make any modificatios to the resin models but use them to help consider the proportions and details.  They are passed around thw workforce before work begins so that every worker has an idea of how the model will look.  It is rare that we copy the exact features from a resin model.  Sometimes it's important to modify the posture so that our statues stand upright and we-ll balanced.

Step 2:  Acquire Raw Materials

We get deliveries twice a week ffrom scrap metal providers.  These include Ford Thailand,  manufacturers for the Thai army, construction companies, boat manufacturers and scrap yard dealers.  On occassion we purchase specialist part from manufacturers around thailand which may or may not be second-hand.

Step 3:  Creation

We begin by creating a wire frame 'scaffholding' for our work.  This provides all the artists with the required proportions and enables them to work alone on each limb. 

It is rare that only one artist will work on a model in its entirity.  Each artist has unique skills and experiences and a large model may require the skills of 10 or more men.  Most artists work unsivervised although each porject is overseen by the master artist who offers assistance and advice.

The working conditions are modest at best.  Whislt there has never been any injuries in the workshop it is certainly not a place for children.  Welding torches are permenantly on, the raw materials are often sharp and perhaps rusted and all the largest statues could invoke serious injury if they fell onto somebody.  Workers wear protective glasses and thich cloves at all time.  Aside from just welding there are toold for bending and beating metal too. 

Step 4:  Cleaning & Laquering 

There is a huge difference between the statues before and after they are cleaned.  We do this at the last possible time as the workshop is usually quite dusty.   We use a clear lacquer most of the time but for models that will be used outdoors we have to use something waterproof.