THE STEP-BY-STEP PROCESS
Below is the step-by-step process by which Sewah Studios produces fine-quality cast aluminum historic markers. The process reads from left to right, top to bottom.

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Prepare pattern layout	Attach letters to pattern	Place pattern face-up on bottom board
Sift facing sand onto pattern	Position mold flask and clamp	Fill flask with molding sand
Pack sand with air hammer	Place new bottom board on mold and clamp	Flip mold over and remove clamps
Remove bottom board	Lift pattern from sand	Pat sand firm with hand trowel
Pat sand in seal / emblem	Cut gates in sand to channel molten metal into mold cavity	Tilt mold and blow loose sand away with air hose
Place mold on bottom board and repeat process for top half	Transfer molten metal from melting furnace to pouring ladle	Pour molten metal into mold
Remove casting from sand and hose down with water	Saw gates off of casting	Remove rough edges from casting with air chisel
Grind letter faces and casting surface	Repair flaws and pits in casting	Spray paint two coats of background paint and bake dry
Airbrush special detail when required	Roll paint on raised letters	Apply gold leaf to letter faces when specified
Final touch-up prior to baking dry	A sample final product prior to wrapping for shipment