Fitting the bones along the steel bars

3. Fitting the bones along the steel bars

Now we are going to do the constructing. We first construct steel bars and then fit each bone on them. Much attention is required because we do not want to damage the fragile fossils by the robust steel frames.
Usually this process was rarely finished at a stretch, as we had to reexamine the positions and postures along with each step we take.

Holding the fossils with steel bars and clamps

Before talking about the process of mounting, here are the basic parts for armature structure;

[Photo:Armature structure,Subframe,clamp]

Subframe and clamps support the fossils. Subframes are attached to the robust armature structure.

Armature Structure
A steel bar to hold each section classified in chapter 1.
Subframe
A steel bar running along the outlines of the fossils and connected to the armature structure.
Clamp
A thin and long steel bar to hold the fossils to the subframe.

Since armature structure requires enough strength to support the whole body weight, cutting and bending such a robust steel frame is quite difficult work. This triple-layer supporting structure enables the work to be done much easier. For some complicated bones such as vertebrae and pelvis, sometimes two subframes were needed.
Even though the steel bar has to be strong enough to hold itself and the fossils, it should not be so outstanding. We try to place the supports to the inner side of the skeleton, so that won't be seen apparently from the outside.

"The supports should be as simple as possible. If you bend them this and that way, everyone will find the supports before seeing the fossils. You have to let the supports run quietly along the fossils because the fossils are what we want to see there."
--- mounting staff

As a consenquence, the following is the way we reconstruct and mount the fossils;

STEP 1	Make gauges
STEP 2	Make steel bars
STEP 3	Make clamps and attach them to the fossils
STEP 4	Build them up together
STEP 5	Take them all to pieces temporarily and paint the steel bars
STEP 6	Rebuild them all together

Let's see each process step by step.

STEP 1. Make gauges

It is indeed hard work to bend those steel frames which are strong enough to support the whole dinosaur fossil. A gauge could help to make this work more easier and effective. First we make a gauge with a steel plate we can easily bend by hand, and then bend the strong steel bars following that gauge. The thin and long steel plate used for the gauge is 8mm wide and 1mm thick.

STEP 2. Make steel bars

[Photo:bent steel frame]

subframe bent along bone

By bending steel frames along the gauge, we make the armature structures and subframe. The main steel frame is 16 to 18mm wide and9mm thick. We use heavier frames for the lower parts of the armature structure, and lighter ones for the upper parts. A special tool callled a 'bender' is used whenever we cannot bend the frames by hands.
For the subframe, we use steel plates of various width and thickness. We sometimes use the benders and sometimes use pliers.

STEP 3. Make clamps and attach them to the fossils

Clamps are used to attach the fossils to the subframe. The clamps are 3mm wide thin steel plates bent and formed by pliers. On one end we make a hole to screw them to the assistant support.
Two clamps from one point of the subframe are bent along the curves to each cover the right and left side of the fossil.
If fossils are heavy, we put some sponge on the meeting surface of the assistant support and perhaps also on the clamps supporting that part to prtect the fossils. We NEVER make a hole in the fossil and screw it up.

[Photo:back of caudal vertabrae] [Photo:back of skull]

Caudal vertabrae of Saichania with steel frame

back of skull of Saichania

[Photo:right foot(front)] [Photo:right foot(back)]

right foot of Saichania

back view of right foot of Saichania

-> 4. Reconstruction Completed!

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dino-master@town.kanna.gunma.jp