New article in the EXARC Journal

I wrote a brief article about the Bronze Casting Festival for EXARC, a journal dedicated to experimental archaeology and open air museums. This year the EXARC Journal has become open access, so the articles are available for everyone to read.
The article is a condensed version of the experiments and bronze casting that went on at the festival at the Bronzezeithof in Uelsen last May. Those of you who support me through Patreon for $5 per month will have already read this and much more in far more detail.
https://exarc.net/issue-2017-3/mm/bronze-casting-festival-bronzezeithof-uelsen-germany
If you have an interest in experimental archaeology, or are just curious about how people did things in the past, without the benefit of heavy machinery or computers, definitely check out the EXARC journal. There are years’ worth of articles that not only tell you how the pyramids could have been built to how impressions in tiles can tell us about ancient textiles.

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Nobody’s Perfect: Contrasts in Craft session at the Nordic Bronze Age Symposium

 

It was my pleasure to present a paper at the Nordic Bronze Age Symposium in Oslo earlier this month. I spoke about recognising the learning process by examining mistakes in metalwork. It was a great session and I hope that the research presented here will spur others to examine the flaws in objects to understand the processes of craft production.

Too often artefacts are selected for examination and display because of their perfection, but perfection can limit us. We see the end product but by the very process of achieving perfection the traces of the journey to mastery are erased. When we examine flaws, both minor and major, a world opens up.We can follow the movements of the artisan’s hands and see the sequence in which an object was made. We can see the choices made during production. Was there a flawed section of decoration because a master artisan was momentarily distracted, or was it because an apprentice was still awkward using tools? We can also question why the flaws remain; why the object survives, rather than having been destroyed or repaired.

The flaws, repairs, and mistakes all contribute to the object’s biography and allow us a glimpse of craft and decoration in ancient cultures. The papers presented in this session examined these and more subjects on mistakes in craft, and generated lively discussion.

“Nobody is perfect: contrasts in craft – for the first time at an archaeological conference artists, craftspeople and archaeologists gathered together to discuss the potential of mistakes, failures and repair within material culture of the past. The results were stunning: mistakes, failures and repair can not only help to identify skill level and apprenticeship in craft, they also indicate the intention, the actual purpose of an artefact.” – Heide W. Nørgaard

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Textile Tools in Archaeology

Archaeological textiles is a difficult specialty since most of the material deteriorates rapidly. It is rare when prehistoric textiles are recovered. However, what textile archaeologists do have for study are the tools used in making textiles: spindle whorls, loom weights, combs, and other tools. When I go to museums, I often look at objects outside of my own area of interest and in the following pages, I’ll be providing some support for my friends who work in textiles.

Some resources for those of you who are interested in historical and ancient textiles include the European Textile Forum whose mission is “…to give academics and craftspeople working with historical textile techniques a place and opportunity to meet with each other. This is the perfect surrounding and the perfect place to solve technical questions regarding your textile and to get input from others working on similar pieces – both on the academic and on the craft side.”

Please note that many of these photos are taken from outside glass cases and can’t provide measurements and weights. However, I will do my best to provide as much information about the context as possible. Click on the thumbnails below for a larger image.

For more information about textiles in archaeology and history, I can recommend the books below. Click on the image for a direct link.


Elizabeth Wayland Barber Women's Work: The First 20,000 Years - Women, Cloth, and Society in Early Times

Craft Specialization and Social Evolution: In Memory of V. Gordon Childe edited by Bernard Wailes

Marie-Louise NoschC. Gillis Ancient Textiles: Production, Crafts and Society

Fanfani, GiovanniMary HarlowMarie Louise Nosch (Editors) Spinning Fates and the Song of the Loom: The Use of Textiles, Clothing and Cloth Production as Metaphor, Symbol and Narrative Device in Greek and Latin Literature

Lilli FransenShelly Nordtorp-MadsonAnna NorgardElse Ostergard Medieval Garments Reconstructed: Norse Clothing Patterns 

Marianne Vedeler Silk for the Vikings

A brief selection of articles and other resources:

Chittock, Helen 2014 Arts and Crafts in Iron Age Britain: Reconsidering the aesthetic effects of weaving combs. Oxford Journal Of Archaeology 33(3) 313–326

Gleba, Margarita 2012 From textiles to sheep: investigating wool fibre development in pre-Roman Italy using scanning electron microscopy (SEM). Journal of Archaeological Science 39 (2012) 3643e3661

Mårtensson, Linda, Marie-Louise Nosch, and Eva Andersson Strand 2009 Shape Of Things: Understanding a loom weight. Oxford Journal Of Archaeology 28(4) 373–398

Rast-Eicher, Antoinette, Lise Bender Jørgensen 2012 Sheep Wool in Bronze Age and Iron Age Europe. Journal of Archaeological Science 40

Shishlina, N.I., O.V. Orfinskaya And V.P. Golikov 2003 Bronze Age Textiles From The North Caucasus: New evidence of fourth millennium bc fibres and fabrics. Oxford Journal of Archaeology 22(4) 331–344

Standley, Eleanor R. 2106 Spinning Yarns: The Archaeological Evidence for Hand Spinning and its Social Implications, c ad 1200–1500. Medieval Archaeology, 60/2

Webb, Jennifer 2002 New Evidence for the Origins of Textile Production in Bronze Age Cyprus. Antiquity 76

Italy

Textile tools in the Bologna Museum of Archaeology

Museum Website (in English)

I took some photos of textile tools while on a recent trip to the Museum of Archaeology in Bologna. The cases were nicely organised by context. That is, rather than group all the spindle whorls together and all the beads together somewhere else, the objects were grouped according to where they were found. For example, if they were found in a burial, all the grave goods were displayed together, so all the beads, spindle whorls, and other objects were on the same shelf with a card explaining the context and how the objects relate to each other. I have undone this a bit because the focus here is on textile tools. However, I will provide as much information as possible so that you will be able to do further research if you wish.

Spindle Whorls and Weaving Weights

Bobbins (Rocchetti)

Spindle whorls and Spindles (Conocchie)

Representations of the Textile Industry

This object, a Tintinnabulo, described as a ritual pendent was part of a lavish burial in Tomb 5 of dell’Arsenale Militare (700-675 BC, Villanovan III) and depicts the steps in wool processing. Drawings show the engravings that are on the front and reverse of the tintinnabulo. More about the tintinnabulo and the burial can be found here.

 

Textile tools in the The Civic Museum of Archaeology and Ethnology, Modena

Museum website (in English)

Textile tools in the The Civic Museums of Reggio Emilia

Museum website (in English)

Reggio Emilia is a small city to the northwest of Modena, along the via Emilia heading towards Milan. Like Modena the exhibits are chronological and just about everything is on display. It’s interesting to note the similarities and difference between the textile tools given how close Bologna, Modena, and Reggio Emilia are.

Textile tools in the The National Archaeological Museum in Naples

Museum Website (in Italian, the English version doesn’t appear to be working)

Norway

Historical Museum, Oslo

Museum website (in English)

The Viking Ship Museum

Museum website (in English)

The textiles and tools come from the Oseberg boat burial. The boat was built in AD 820 and was in use until AD 834 when it was used for the burial of two women. The burial includes two chests that contain textiles woven from linen and wool, tapestries, and textile tools including a swift, distaffs, weaving tablets, shears, and looms. Raw materials, such as bundles of unspun flax were also a part of the goods interred with the women.

England

Unlike Italian museums, the ones in the UK display only their finest examples with much of the collection in storage. The museums here are arranged by city, roughly from north to south.

Arbeia Roman Fort & Museum, South Shields

Museum website

Segedunum Roman Fort, Baths & Museum, Wallsend

Museum website

Hancock Museum, Newcastle

Museum website

Bede’s World, Jarrow

Museum website

Museum of Archaeology, Durham

Museum website

Wiltshire Museum, Devizes

Museum website

The Museum of Somerset, Taunton

Museum website

The Meare Lake Villages near Taunton was a major craft manufacturing site during the Iron Age in Britain (800 BC – AD 100) and more bone combs were found there than in the rest of Britain combined. It would be interesting to find if anyone has done a study to see if other bone combs in Britain and neighbouring regions can be traced back to Meare or Somerset. The combs are distinctive and carved from whalebone.

Royal Albert Museum, Exeter

Museum website

Iron Age Spindle whorls Royal Albert Museum, Exeter, UKIron Age Spindle whorls

Iron Age Spindle Whorls.  Royal Albert Museum, Exeter, UKMedieval spindle whorls made of bone and lead

Northern Ireland

Ulster Museum, Belfast

Museum website

Bone weaving tablets (the large one looks like a scapula), spindle whorls, a distaff, and shears. AD 8th-10th Century. Ulster Museum, Befast, Norhtern Ireland.
Bone weaving tablets (the large one looks like a scapula), spindle whorls, a distaff, and shears. AD 8th-10th Century.

 

 

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The Mavis Furnace: Casting in Albuquerque or how to build a furnace for almost no cost!

This autumn I was visiting my sister who lives just outside Albuquerque, New Mexico. She has a bit of land, so I asked her if I could build a furnace and do some casting there. I’ve built plenty of pit furnaces, so this time I wanted to build one that was above ground and a bit more visible. It would also mean that no one would trip and fall if they forgot where I put the thing.

First off was to get the basic materials: Clay, Sand, and Horse Manure.

I thought that the clay would be the biggest hurdle. However my sister’s neighbour happened to be a sculptor who works in both iron and ceramics. She went to her regular clay supplier and got a couple feed sacks full of dried clay for free! Potters who work at wheels, or work with kids end up with a lot of clay that is scraped off of workbenches and wheels that is hard to re-use. It’s often mixed consistency, lumpy or part dried. If they want to use the clay again, it has to be reconditioned. So, they take their sacks of scrap back to the place where they buy the clay and pay to have it put through the mill. Since it’s not really usable, some potters are willing to just give it away. So thanks to Liz Fritzsche, who does amazing and beautiful work in porcelain, I was able to get started.

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Dry clay

I threw some of the dried clay into a five gallon bucket and poured in enough water to cover the clay and let it sit. It was squishy and workable in a few hours. Next up was horse manure. A friend of a friend has horses, and they were grateful to have someone who would haul away a couple of barn buckets full. The final bit was the sand. My sister did have some beach sand that she’d bought for the garden, but I was more fascinated by the soil there. Her land is in the old Rio Grande River Valley, and the soil is a mixture of silty sand and a little clay that had been pounded to a powder. The soil was almost the consistency of dust. It mixed in perfectly and later I found the mixture was highly resistant to cracking.

The ingredients were mixed with some water, stomped, and adjusted. New Mexico is a lot drier than England, so I ended up adding more water as I worked. It was also nice knowing that it was unlikely for any rain to fall while I was working.

The silt/clay/dung mixture made a durable clay, and after I flew back to Minneapolis, I was please that the crucibles and moulds I packed in my check-in luggage survived airport handling.

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The Mavis Furnace: note the small tabs inside. These support the Teapot Stand.

The furnace walls are about 8 cm wide (about the width of my palm) and the inside diameter is about 25 cm in diameter. I let it dry for a couple days and then moved it over to an unused area behind a greenhouse where I would have more room to work. I set a small fire with cottonwood branches, fed it for a couple hours, and then let it die out overnight.

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Mavis the dog immortalised in a furnace!
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Mavis in a calm moment. Her nickname is the Dog-nado.

 

 

 

 

 

We all like to put some decoration on our furnaces. My students have done everything from dragons and demons to cats. I had been thinking about doing some imitation petroglyphs, but as I was working it just seemed natural to do a portrait of Mavis, my sister’s exuberant German Shepherd.

Finally I adjusted the mix to have a bit more of the silty sand and horse dung to make the teapot stand and crucibles. For more information about teapot stands and how they work in furnaces, check out my article on the Umha Aois website here.

Later I added more water to make the slip for dipping waxes in for the first stages of mould making. The silt made a wonderfully fine mould that picked up all the details.

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The Mavis furnace, teapot stand, and some crucibles

I had some cracking on the upper part of the furnace, and noted that the part that cracked was where I used the commercial sand. The silty New Mexico soil held up much better. If it weren’t so heavy (and probably not allowed) I would have hauled bags of it on the plane to use for more projects.

Both Mavises performed very well (Mavis the Dog is into barrel racing and advanced obedience classes).  I’ll be interested to see how it holds up over the winter. Winters in New Mexico tend to be mild, so I’m hoping that the Mavis furnace will be available for friends in Albuquerque to use for some time to come.

 

Here’s a very short video of the furnace in action.

 

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Iron Age shoes

 

Sometimes you just need a new pair of shoes. I’d been wanting to make some of the replica shoes I’d seen online. there are a few good sites where you can find patterns and step by step tutorials.

Kelticos has a number of different patterns that you can download.
I followed the instructions on this site. It goes step by step and practically no-fail. I however am a bit more cautious and rather start with the leather I made a pattern out of brown paper.

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brown paper pattern for a pair of Iron Age shoes.

 

Once I was confident that I had a good fit with the paper pattern, I bought the leather that I needed. One thing that few sites describe is the type and weight of leather needed. I bought some cow leather that was supple, but not stretchy from Cox Leather in Abuquerque. The place is an amazing resource for hides, rawhide, leather, skins, and really anything leather related. They also ship!

Leather thickness in the US is measured by the ounce, and in mm in Europe. The leather I bought was about 8 oz / 3.2 mm / 1/8 inch thick.

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The pattern laid out on the leather. I traced the right foot and then flipped the pattern over to trace the left foot.

 

Once I traced the pattern on the leather, I cut the shoes out using good sharp scissors and punched the holes for lacing with an awl. It’s important to use an awl or punch rather than cutting the hole with a scissors since a round hole pushed through the leather is less likely to tear than a hole that is cut.

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The shoes all laced up.

I stitched up the backs with sinew. I followed the directions and stitched the sides of the heel to the heel tab straight up. It ended up a little loose. When I get the time I’ll restitch them so they come in a little tighter on the top. Another modification will be to put more of a sole on them. Some options are to cut an insole out of rawhide and sew it between the inside of the sole with another, softer leather insole on top. I might line it with some sheep skin, too.

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A comfy fit.

 

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Casting with Dr. Billy Mag Fhloinn

I’ve been honoured to cast alongside Billy on a number of occasions while we were both at Umha Aois events. His recent article for the Pallasboy Project: Art, Craft, Archaeology, and Alchemy talks about his experience in both experimental archaeology and craftsmanship.

 

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Bellows Forum

I have a fascination with bellows. We know they had to have existed in the Bronze Age, but unfortunately they are also constructed of ephemeral materials, so none have survived into modern times. The only physical evidence we have consists of fragments of tuyeres. An Egyptian painting from the Tomb of Rekhmire, from 1450 BC shows a man using pot bellows that are operated by hands and feet. There are also Chinese documents depicting the use of box bellows. But bellows, after blowpipes, are likely to be one of the earliest forms of delivering air to the furnace.

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Scene from the Tomb of Rekhmire. The man on the right is operating a set of pot bellows. The valve is opened when he lifts both his foot and pulls on the cord attached to the top of the bellows. The air is pushed out of the bellows when he steps down. These require a lot of coordination.

Until a set of bellows is uncovered preserved in a bog somewhere a lot is left to the imagination. How big or small could they be? How can the valves be altered to be more efficient? How heavy should the leather be? Should sturdiness trump suppleness? How are all the parts held together and made airtight? Bellows are one of the most essential pieces of equipment that we have for casting bronze and yet very little information is available about their use and construction from the community of experimental archaeologists and reenactment groups.

Over the years I’ve seen many different shapes and sizes of bellows and always thought that a forum where bellows design and use could be discussed would be invaluable for people to share ideas and experiences.

I would like to invite others to share photos of the bellows they’ve made on this site. This could be a welcome forum for discussing the pros and cons of different designs, what worked, what didn’t. Of course any news of archaeological bellows or tuyeres discovered would add to the fun.

To start, Martijn van Es sent me some photos of a set of bag bellows he made and photos of a new set he recently completed using the tutorial on this website. Martijn casts bronze at the Bronzezeithof Uelsen and Het Bronsvuur – The Bronze fire and is active on the web and Facebook discussing Bronze Age casting techniques and projects that he’s involved with.

 Other bellows designs

I saw these pot bellows in use at Arbeia Roman Fort several years ago. They incorporate partially hollowed tree stumps and circular leather bags with the valve on top. This is one set of bellows that won’t shift around!

Roman reenactors at Arbeia Roman Fort in South Shields, UK using a portable furnace and pot bellows
Roman reenactors at Arbeia Roman Fort in South Shields, UK using a portable furnace and pot bellows

 

This has to be my favourite bellows idea. Simply made from two cement bags.

I welcome others to send in photos of their bellows, and not just bag bellows. Any bellows that could be considered to fit in with what we know or can surmise from archaeology would be interesting for this forum.

If you are interested in making bellows for yourself but don’t know where to start, check out the tutorials on my site for making bag bellows and for making pump bellows.

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World’s Oldest Needle

World’s oldest needle found in Siberian cave that stitches together human history

Bone needles are one of those things that are a useful part of any experimental kit. They are easy to make, durable, and work better for sewing leather and hide than many steel needles. If they do break, then it’s easy enough to cut off a new bit, drill a hole and sand it down to a glossy, slender tool. The best bones to use are the long bones, a humerus or femur.

Recently a particular bone needle made the news. A 7 cm needle made from a bird bone was found during an excavation in the Altai Mountains in Russia. You can read the full article here. Finding a needle in an excavation is difficult enough, but finding one intact after 50,000 years is extraordinary.

However, in this context this needle is much more than just a needle. First we must think about the technology and tools that went into making the needle. It had to be cut and shaped with stone tools, and then there’s drilling out the eye. Once we start thinking about making something as simple as a needle, suddenly an entire toolkit appears, and then there’s the other direction: how was the needle used and what was it used for? Materials such as leather, string, and textile rarely survive in the archaeological record. Could the Denisovans have been sewing hides into clothes? Making shoes? Sewing smaller skins into something larger such as blankets or tents? A world of missing material culture suddenly becomes imaginable.

Small things like this needle should put to rest the image of the “caveman” with ragged animal skins. These people were likely to have been sewing clothing!

 

 

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Making Tuyeres

Tuyeres are the tubes that bring the air from the bellows to the furnace. They can be made of wood, ceramic, PVC pipes, copper pipes, really whatever you can come up with that will do the job. They are usually connected to the bellows, but in some cases they can just be set close enough that the air is delivered through them to the furnace. If you have a set of two bellows, the tuyeres are in a “Y” shape, with two ends connected to the bellows that connect to a single end going to the furnace.

Archaeologically there aren’t many remains of tuyeres. There are some fragments of tubular ceramic objects that had evidence of burning on the end. However, the best example is a wooden one recovered from a Danish bog. This was the same sort of “Y” shaped one described below.

Quick and easy: Tuyere #1

One of the problems of working with kids is that they are so fascinated with flames that they sometimes don’t realise that the bellows aren’t the part that supposed to be burning. So I’ve been working on making a couple of new sets of tuyeres.

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Poor tuyere. Burnt to a crisp! I guess that it’s time for a new set.

I’m under a deadline for one set, so this one is a quick and easy version. I pulled a good sized forked branch from the woodpile and cut the ends so they were fairly even.  Then I got a 22 mm spade bit (aka: a flat bit). Then I just clamped it into a vise and drilled into the flat ends of the wood until the holes met near the centre. I removed the bark, rounded off and sanded the ends. I don’t want any bark that will work loose over time, or any sharp edges that will abrade the leather.

These will be connected by leather tubes to the bellows and held in place by strips of rawhide. Skip down to the section on putting them all together for the details on that.

Note: Save that sawdust you’re generating with all that drilling. It will come in handy for making moulds!

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I usually like one with a wider fork, but this will do in a pinch. It’s more important that the two ends are close to the same angle from the main trunk to minimise any kinks when connecting them to the bellows.

 

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Holes drilled. All that’s left is to attach it to the bellows.

 

Larger and more labour intensive: Tuyere #2

The next one is another wooden tuyere for a new set of bellows I’m making. It’s larger, so the spade bit isn’t an option. Instead I cut the wood in half lengthwise and then carved out the inside with a gouge. It’s all handwork, so it takes longer, but one advantage is that the diameter of the air holes isn’t limited to the size and length of the drill bit.

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This is a section of a branched trunk with a good angle. Most of the bark is removed and the wood looks sound underneath. Time to slice it in half.

The first step was to trim the branches and strip off all the bark and then saw it in half. Once it was cut, I marked off where I would carve out the centre and went at it with chisels and gouges. I made the interior as smooth and as even as possible. However, I don’t smooth the surfaces that will be glued together. They already fit well and the rougher texture will help the glue bond.

Ceramic and other Tuyeres

If your tuyere might be placed close to the furnace (as mine accidentally was), it would be a good idea to make a ceramic extension. This is just a tube made of the same ceramic you used for making the furnace or moulds. It can be fit to the end of your wooden tuyere with leather and rawhide, as described below, and the end can go straight into the furnace. The only problem I find with ceramic tuyeres is the possibility of them breaking when being transported or if someone steps on them.

At the Terramare Village in Montale, the tuyeres they use there have a 90 degree bend. The tuyere sits on the edge of a small, shallow furnace and blows air straight down onto the charcoal. It’s an Early Bronze Age design and does get hot enough to melt bronze and copper. If you don’t have much space for a furnace this would be an ideal solution. It’s also worth experimenting with different types of furnaces and set-ups to get an idea of how many solutions there are to the basic question of how to melt and cast metal.

I’ve also made tuyeres using the stems of Japanese knotweed. The stems are hollow, similar to bamboo, but much softer. The plants can get over an inch in diameter and several feet tall. The stems can be easily cut with a knife, small garden shears, or secateurs, and then the membranes between sections can be broken using a straight stick. Note: Japanese knotweed is a controlled invasive species in Britain. Any fragment of stem, leaf, or root will take root and start a new plant. They are almost impossible to get rid of once started. When I find a large stand of knotweed, I strip off any leaves and excess stem and leave them there. If I need to trim off any more once I’m home, I put it in a plastic bag and then put it in the bin.

As I said earlier, tuyeres can be made of anything that will get the job done. If you don’t need to have that “authentic” Bronze Age look, you can quickly whip something together with PVC plumbing or copper piping. It wouldn’t be glamorous, but as long as any flammable or melt-able parts are kept away from the heat of the furnace, it should get the job done.

At the EAA in Glasgow, I saw a poster showing the reconstruction of a beautiful horse-headed ceramic tuyere by Katarina Botwid of Lund University. You can see the tuyere in action here.

Putting them all together

The tuyere still needs to be connected to the bellows. I usually make tubes of leather that fit the tubes coming out of the bellows and the ends of the tuyere.This allows for some flexibility and gives you a bit more distance from the furnace.

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A tight stitch and a decent amount of overlap will make these pretty airtight.

Then I tie them in place with wet rawhide. Once the rawhide is dry, they are about as secure as you can get. If the leather is soft, the tubes have a tendency to twist or collapse, so a nice solution is to get some green willow twigs and roll them into a spring. Fit them into the tubes before doing the final attachment and they’ll keep the leather tubes open and prevent them from twisting.

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Everything is fit together and tied with damp rawhide. Once the rawhide is dry, the bellows are ready to go.

 

By the way, if you have a hard time finding rawhide lacing, buy a rawhide dog chew. Soak it in a bucket of water overnight and then cut it into long strips while it’s still damp. If you don’t need all of it right away, let it dry out. Then when you need it again just soak it for a few hours and it will be nice and flexible again.

 

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Casting Bronze in the Italian Bronze Age Way!

This month (October 2015) I had the great adventure of doing some bronze casting with Il Tre de Spade (The Three of Swords) at the Archaeological Park and Open-Air Museum of the Terramare in Montale. The museum is located just south of Modena and recreates Bronze Age houses surrounded by a palisade and a marsh, appearing as it would have in the central and later phases of the Bronze Age there (1600-1250 BC). The museum hosts demonstrations and activities, along with a recreation of the original excavation.

The houses are nicely furnished, with well laid out areas for cooking, sleeping, food storage, and workshops. One house has a workbench for wood and antler working, along with weaving and other crafts. The other has a metalworking workbench with stone anvils, moulds, bellows, and all the needed kit stored neatly on shelves and a work bench. Unlike the recreated roundhouses that are often seen in the UK, you can get a good idea about how the ancient people lived here and where they put their all the things they used in every day life.

(Click on the thumbnails here to see a larger version)

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The ubiquitous Bronze Age warp weighted loom. This one has some rather nice textile in the works.

 

 

 

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The cooking hearth and oven. The little device on the side is a wonderful little warming oven with charcoal in the bottom and the food on top. I like to think of it as a Bronze Age microwave.

 

 

 

 

 

 

 

 

 

 

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Pots on a shelf

 

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Space for metalworking tools and supplies

 

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Wood and antler working area.

 

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some of the woodworking tools.

I had been invited to join the casting demonstrations by Claude Cavazzuti, who is also part of EXARC. He is one of Il Tre di Spade (along with Pelle and Scacco) , who were some of the first metalworkers at the museum after it opened several years ago. They do regular demonstrations (sometimes with hundreds of visitors per day) and also run workshops that introduce people to Bronze Age casting and metalworking with a focus on the  Middle and Recent Bronze Age (1700-1150 BC) of Northern Italy.

The furnaces there are small clay-lined trenches about 25 cm deep and 50 cm long, something that would be nearly invisible archaeologically and easily interpreted as a cooking hearth (and really, there’s no reason why they couldn’t be both). The furnaces heat up quickly and work efficiently. The charcoal is concentrated around the crucible with more warming beside it so that the fuel is hot before it gets raked around to cover the crucible.

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The furnace. Not much to see here, and even less after a few thousand years!

My first new introduction was the bag bellows. They were larger than I have used in the past, and made of heavier leather. They put out an enormous volume of air, but also their size allows the person pumping the bellows to sit on a low stool. One nice innovation is that they put a large stone in the bottom of each bag. That prevents people who are new to bellowing from lifting them too high and causing the bags to collapse.

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The real challenge for me was the valve and the way the bellows open at the top. The bag bellows I’d used before have straight sticks in the handles that either open parallel to each other, or are hinged at the back to open like a “V”. These bellows have two sticks on both sides, so that they open into a diamond shape with the wide part opening where your hands hold the bellows. It took a little bit to get used to them and to figure out where best to position my fingers. I never did get it quite tight enough and could feel a bit of air blasting on the back of my arms, but they still  delivered a powerful amount of air. The tuyere was a large clay tube that curved downwards at a 90° angle, and was positioned so that it was directly above the crucible. This mean that the charcoal had to be moved frequently to keep the crucible covered. Without the layer of charcoal above, the air coming from the bellows would cool the metal in the crucible.

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The tuyere with the moulds set next to it to warm up. The small bowls are the crucibles. Note that they are used without lids.

The crucibles are a flattened dish-shape, with some that were larger and a bit more of a bowl shape to hold more metal. They have a tab on one side that is used as a handle. The crucibles have a small lip for pouring that causes the metal to pour more quickly and flow out in an arc, rather than almost straight down like the triangular bag-shaped bellows used in Britain. It took a little bit of getting used to the trajectory of the metal in order to get all the metal in the pouring cups.

The tongs they use are beautifully crafted from wood and cord. They are kept in a bucket of water to keep them from burning when holding the heated crucible. The entire organisation of tools and materials is efficient and elegant, and there is nothing that would not have been found archaeologically from this period.

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Beautifully constructed wooden tongs

For the first demonstration a sword was cast into a sand mould. The sand they use is local, and perfect for casting. Commercial casting sand consists of fine sand and dry bentonite clay. The sand from the Po River delta is exactly that, sand that has been reduced to almost a powder by erosion, combined with clay and silt that has been washed into the river. The Po River sand leaves a much finer texture on the finished objects than the coarser commercial sand that I have used here. Looking at the quality of the sand, I could imagine how different sands might affect the regional quality of casting, and might even have had value as a commodity.

The mould for the sword was made using the standard cope and drag method, with the pouring cup on the side of the sword, rather than pouring from the top. A large vent was also placed at the tip of the sword. The mould was placed at an angle. As the crowd gathered and settled onto benches under a marquee, Claude explained Bronze Age metalworking techniques and then the sword was cast. Everyone was impressed and even more so when the sword was taken from the mould.

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The sand mould is set up. The hole at the top is the pouring cup. There’s a smaller hole at the bottom, at the tip of the sword that acts as a vent.

 

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Casting the sword.

After the demonstration was done we started up a second furnace for the workshop. For this one we used the stone moulds that were on display in the house. The moulds were made of a very fine grained local stone, the same that had been used by the Terramare circa 3500 years ago. The moulds were warmed next to the furnace and then strapped together with leather strips. We took turns bellowing and pouring. The shallow crucibles mean that the pouring has to be done more quickly than with deeper crucibles. They cool quickly, so there is little time for dragging out charcoal and skimming. Once the metal was molten, we gave it a quick stir with a stick, pulled the crucible out with the wet tongs, and poured the bronze into the mould while holding the stick across the top to keep the charcoal back.

Sickles, knives, and daggers were cast. Later we moved on to using sand moulds. I borrowed one of the antler spindle whorls from the woodcarving house to see if I could try casting that as an experiment. It worked sort-of. It will take a bit of work to get finished up, but I think with a couple more tries we could have got it spot-on.

I was wearing my bronze torc bracelet that day and one of the new people wanted to try casting that. We used it as a model for a sand mould and after a couple tries, we got a cast that made a perfect duplicate.

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A display of some of the things cast at the Open Air Museum

While we were casting, more tour and school groups came through to watch more casting demonstrations. School kids also had the opportunity to make their own copper bracelets. There was a square of tables set up with small stone anvils and hammerstones. Punches and chisels were available so they could decorate the strips of copper to make bracelets in patterns that would not have looked out of place in a Terramare village.

Often after the casting is done for demonstrations the bronzes are taken home and finished up using drills and angle grinders, but not here. We had a relaxing time using wet sand on the hard, fine-grained anvil stones to grind off the flashing and excess metal. Some smaller stones that had a coarser texture could be held in the hand and used for working the inside curves and corners. I’d brought my small socketed hammer along and we used that to break off some of the metal, too. Between light hammering and patient grinding, the daggers were smoothed rather more quickly than I would have expected.

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A nice flat anvil stone for grinding the flashing off of the dagger blade. There’s evidence from the originals that the holes for rivets were punched rather than drilled, or cast in place. Other stones are used for coarser grinding. Note my hammer at the bottom. It came in handy for breaking off some of the flashing. A bit of time travel here since this is a replica of a Late Bronze Age hammer!

It was a great day, and one that was full of new experiences. It was particularly interesting to see how much variation there is in doing the same tasks and getting successful results. The different types of bellows and crucibles make for differences in how tasks are performed. Other small acts show variation between different metalworking groups. Tasks such as turning the crucible over to remove dross and leftover metal after casting was done into the furnace here, where in Ireland we have always done that next to the furnace. These are small things that could be seen archaeologically if excavation is done carefully, but also shows how customs and metalworking traditions develop with regional differences.

Next month I will be moving to Modena and will be in the vicinity of the park. I hope to do more casting there and to learn more about the Early Bronze Age metallurgy of Northern Italy.

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Dagger: This was cast in a stone mould and is partially cleaned (it’s the same one as in the photo above). The pouring cup will be cut off and rivet holes punched into the arched end.

 

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Knife: This is as cast in commercial casting sand. It will take a bit of polishing, but I am looking forward to finishing and using it.
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Sword: This was cast in the natural sand. It’s difficult to see, but the texture is much less gritty than the knife. It’s about halfway between the knife and the dagger for smoothness. It just needs to have the sprue and vent removed and a bit of the flashing taken off before punching the holes for the rivets.

 

A special thanks to Il Tre di Spade, Claude, Pelle, and Scacco and the staff at the  Parco archaologico e Muse all’aperto della Terramare for inviting me to participate in casting. I would also like to acknowledge Markus Binggeli & Markus Binggeli who are masters of bronze casting and replicating ancient metalworking techniques. They are mentors of  Il Tre di Spade, and provide both inspiration and technical expertise for experimental archaeologists.

Useful links

If you’d like to learn more about the Early Bronze Age in the Modena area, the work of Il Tre di Spade, and the Terramare Open Air Museum in Montale you can find links below.

A film about the Terramare and Bronze Age metalworking (in English)

Italian language sites

Parco archaologico e Museo all’aperto

Musei Modenesi

Parco archaologica sul Facebook

English language sites

Archaeological Park and Open-Air Museum of the Terramare in Montale

Visit Modena tourism

EXARC

Il Tre di Spade also have a Facebook page.

 

 

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