Condar Half Kettletm
How It Works
Condar’s Half Kettle is created from Cast Aluminum in a family owned foundry right here in the USA. First, a detailed set of blueprints are made, showing curves, thicknesses and other dimensions. The Pattern Master uses these blueprints to carve an exact replica of the Half Kettle called the Master Pattern. A second pattern is made to form the inside of the kettle. This second sculpted pattern is necessary because the Half Kettle is a “core” casting, meaning it has a large hollow area that must be formed to exacting standards. Core patterns and core castings are much more complicated (and thus more expensive) than regular “flat” castings.
Next, these hand crafted Master Patterns are used to produce a Production Pattern. The Production Pattern is made from Cast Aluminum, and is cast as part of a large rectangular plate. This plate allows the pattern to be mounted on a special high production mold-making machine. One Production Pattern is made for the Half Kettle’s body, one for the lid and one for the hollow center.
Our Half Kettles are made by pouring molten Aluminum into special sand molds. These sand molds are formed by pressing the Production Pattern into a special sand which holds its shape. One mold is made for the back of the kettle and one for the front. Before the two halves are mated, a core mold is placed in the hollow of the sand mold. This core is made of a special substance which can stand (for a short time) the heat of the molten aluminum. The red hot liquid metal is then poured into the ready mold. The core pattern withstands the tremendous heat for a short time, but once the molten metal starts to cool, the core ignites and is consumed instantly by flames, leaving a cavity to form the inside of the Half Kettle. The sand is then shaken off the Half Kettle, and it is sent to the machine shop for grinding, finishing, and drilling. The Burnished Aluminum version is polished to look much like pewter. The Classic Black version is finished with a high-temperature special paint.
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