My friend Thuri, who has been a professional jeweler for 13 years carved this.
Gee, I wonder who did which bear....
Anyhow, we used a joint compound for our mold, which worked fine for the one time we used it, but does not have any sort of longevity. Last Saturday we (Thuri) carved a mold out of soapstone, which will last through numerous pourings.
Here is the process:
Thuri drawing out the design
The design ready for carving
The carved mold ready for pouring
Heating the pewter. Pewter has a low melt point so it is perfect project to do on the stove. We melted the pewter in a crucible on her gas burner and transferred the melted pewter using a stainless steel spoon (stainless steel has a much higher melt point so it was not effected by the heat of the liquid pewter).
Pouring the liquid pewter into the mold. The soapstone transfers heat a lot better than the joint compound we used for the earlier molds so thicker gloves were in order when handling the mold.
This is not a perfect pour (still missing the top of the spear) but we are getting closer.
The finished bears.
I honestly think our (Her) first bears turned out better so we (She) may carve a new mold and we will try again. The design was a bit big to get the pewter to flow and I think that our sprew was not quite right. Currently the Crown has enough for 4 more reigns (2 years) so we have plenty of time. I'm going to pick up some more soapstone and pewter at Lilies. It was a fun project and now I want to make other stuff, maybe buttons.