Week Four
Time to learn how to manufacture clay. This is very hard work but strangely satisfying. It begins by shoveling clay 'dirt' into a wheel barrow. It is then broken up further and tipped into a large bucket, half full of water. The mixture is stirred with a heavy-duty paint stirrer.
Next, silica and kaolin is measured into the mix and combined. Then the sieving process begins. I wasn't present for this part, but I believe the clay sludge if poured through a series of increasingly fine sieves. The final result is poured onto special plaster-topped tables where the moisture is sucked out by the plaster. When it resembles chocolate, it is cut, rolled up and wrapped in plastic (if it's going to be left for any period of time).
The bundles of rolled clay are next taken to the pug mill table, unwrapped and stacked side by side.
Kiln Wash: A solution of 50% silica and 50% kaolin with water is painted onto the kiln shelves to prevent glaze from sticking onto the shelf.
This week, I continued trying to make identical tumblers with varying success. Getting a bit bored with them.
Relations with the boss also vary. Sometimes he is talkative and gives information when asked. He is often a bit short though and abrupt. He will often prevent me from talking or asking a question. He doesn't like autonomous interns! It is also disturbing because I never know when I am going to give offense. He takes offense easily and unpredictably. For instance, it is a personal insult if I put the pugged clay in the wrong box. Once, I innocently remarked that he could have afternoon tea open days on the property. Well. He raved on for half an hour about people telling him what to do when he knows everything and has done it all!
We had a group of visitors celebrating a birthday, by all having a go making pottery. It was quite an enjoyable morning.
Next, silica and kaolin is measured into the mix and combined. Then the sieving process begins. I wasn't present for this part, but I believe the clay sludge if poured through a series of increasingly fine sieves. The final result is poured onto special plaster-topped tables where the moisture is sucked out by the plaster. When it resembles chocolate, it is cut, rolled up and wrapped in plastic (if it's going to be left for any period of time).
The bundles of rolled clay are next taken to the pug mill table, unwrapped and stacked side by side.
I do not know the finer workings of the pug mill, but I picked up a few rudimentary tips. Before operating, check the oil in the pump underneath. Take out the plastic wrap and moist rags from under the cover of the vacuum pump and under the extrusion handle. Then, once switched on at the wall, begin!
Clay is fed into the top chamber, the handle pulled down and it extrudes out the end. It's quite a process to cut off sections and stack them in a polystyrene box - without letting them fall off onto the floor. After all the clay has gone through this process, the pug mill is cleaned and damp rags are again pressed into the chambers. Plastic wrap is secured across the mouth of the extruder.
The next day, this whole process with the pug mill is done again to ensure there are no air bubbles in the clay. The clay sausage is cut and wrapped into smaller pieces for storage before use.
Before using the blocks of clay, it is essential that you wedge the clay. This involves cutting the lump of clay, turning and smashing together again, many times - about twenty times.
This week, I continued trying to make identical tumblers with varying success. Getting a bit bored with them.
Relations with the boss also vary. Sometimes he is talkative and gives information when asked. He is often a bit short though and abrupt. He will often prevent me from talking or asking a question. He doesn't like autonomous interns! It is also disturbing because I never know when I am going to give offense. He takes offense easily and unpredictably. For instance, it is a personal insult if I put the pugged clay in the wrong box. Once, I innocently remarked that he could have afternoon tea open days on the property. Well. He raved on for half an hour about people telling him what to do when he knows everything and has done it all!
We had a group of visitors celebrating a birthday, by all having a go making pottery. It was quite an enjoyable morning.
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