What we had to do
Our client was working on an exhibition for The National War Museum, the Warhorse Exhibition, illustrating the plight of horses that were involved in the First World War. We were asked to make 3 life size war horses which would be painted white and have black and white clips of war horses in action during WWI.
The polystyrene sculpture
Preparing for the mould
The horses at The National Army Museum
The polystyrene sculptureWe sculpted the horse in polystyrene. The reigns and saddle are made from a medium density from that we cut to shape and adhered to the polystyrene.
Preparing for the mouldThe polystyrene horse with its protective hard coat and shim wall ready to mould.
The mouldThe mould complete with bolt holes all around the flange so that the many parts of the horse can be put back together when we are casting a horse out.
WeldingGetting inside the finished cast horse to weld the steel pole to the internal metal frame so that we can make all three horses free standing.
Three horsesAll three horses painted and on their stands ready for the museum.
The horses at The National Army MuseumHere they are all lit up and looking ready for their first appearance
How did we do it?
The client wanted the horse to look like a shire horse but stylised to a certain degree, so we set about sculpting one horse in polystyrene. We gave the finished sculpt a hard coat so that we could make a fibreglass mould from it. The mould had many parts to it because of the size and stance of the horse. As with all moulds, we had to add a shim around the figure which dictates where the joins will be, and how many parts there will be to the mould. Each horse had to be suspended on a metal pole so that they could be positioned in the Museum in such a way that they would look like they were galloping. We had to fit a metal frame inside the horse and weld a metal pole on to the frame, then make good the access hole, and finally paint the horses white ready for their trip to the museum.
All three horses were the main attraction at the museum and proved to be quite the hit with school children and war veterans alike.