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How to Reproduce Old Bells

Bells have their place in almost every culture in our world, and they may evoke any number of historical memories, nostalgic feelings and musical inspirations. Bells have often been made to commemorate or honor important occasions or people, and though they are often sturdy and long-lasting objects, over time, they may need to be replicated or replaced so that their symbolism and sound may live on or be more widely felt. Reproducing bells is not a casual undertaking, however. It requires a good knowledge of metal casting, along with all the attendant safety precautions.

Things You'll Need

Sturdy wood or metal box, with removable rimmed bottom and top lids, large enough to fit the bell with at least few inches to spare in each direction
Old bell, clapper removed, or plaster model of the bell you wish to reproduce
Casting sand, enough to fill the box
Wood dowel, as long as the box is tall, 1/2 inch to 1 inch depending on the size of the bell
Bronze or appropriate bell metal
Foundry and necessary safety gear
Metal drill
Belt sander, sandpaper or metal polishing cloths (optional)

Instructions

Make the Bell Mold
- 1
  Place the box on a secure flat surface with a lid attached to the bottom only. Place the bell in the box, rim side down.
- 2
  Pour a thick layer of casting sand around the outside of the bell, packing firmly.
- 3
  Stand the dowel straight up in one corner of the box, a few inches from the box edges and the bell. Press the bottom end into the casting sand until it reaches the bottom of the box.
- 4
  Fill the box to the top with casting sand, around the outside of the bell and around the dowel, packing firmly. Leave a small 1/2-inch to 1-inch hole exposing the holding tab at the very top of the bell and also leave the top of the dowel uncovered. This outer part of the mold is the cope.
- 5
  Cover the top of the box with the second lid and invert the box. Remove the first lid and cut a 1/2-inch to 1-inch channel in the sand from the dowel to the nearest outside edge of the bell.
- 6
  Pour casting sand into the inside of the bell, packing firmly, making sure that the top surface of the sand is smooth and even. This inner part of the mold is the core.
- 7
  Let the sand harden, and when it is firm, invert the box and slide out the core, the bell and the dowel.
- 8
  Fill the top that you have removed from the box with a thick layer of packed casting sand, making sure the top is smooth and even. Press the bottom rim of the bell lightly into the sand to create a shallow ring impression centered in the box bottom. This is the base mold.
- 9
  Let the three pieces of the mold harden completely. This may take several days, depending on the size of your bell.
- 10
  Center the core on the base, using the ring impression as a placement guide. Place the cope on the base over the core, using the box edges as placement guides.
Cast the Bell
- 11
  Determine the material and weight of the original bell to determine what metal to use and how much of it to obtain.
- 12
  Prepare the foundry, place the metal in the foundry crucible and melt to its required specifications.
- 13
  Pour the molten metal from the crucible into the hole left by the dowel. Continue to pour the metal into the dowel hole until molten metal rises into the hole you left at the very top of the bell.
- 14
  Leave the bell to cool.
Finish the Bell
- 15
  Break the sand mold from the bell.
- 16
  Drill a hole through the holding tab of the bell for mounting. Drill a hole through the clapper tab inside the bell to attach the ringer.
- 17
  Polish the bell as desired with a belt sander, sandpaper or metal-polishing cloths.

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