Jockey Weathervane
During this course, I wanted to think outside the box about how I could utilize the cast iron final to its full potential while finding ways to maximize the use of the material. I decided to create a weathervane mold so that I could use the iron as a means to produce the final object, rather than having the cast object itself be the final product. Through a lot of exploration, experimentation, and feedback, I eventually settled on the design of the horse. Since my earlier material explorations focused on understanding the casting process and the possibilities of the form, choosing a horse for the final project felt like a full-circle moment.
Creation Date Spring 2026
Course Cast Iron
Materials
Brass, Copper, Steel
01 Form Prototype Exploration
Design Development Developed multiple design concepts and explored a range of forms for the final project.
Gathered peer and expert evaluation on design concepts.
Iterated design concepts based on chosen product for the project.
02 Design Progress
Redesign and Refinement Sketched multiple variations of one design before selecting the most refined version.
Made necessary adjustments to the design based on improvements from feedback.
Prototyping Produced initial prototypes to visualize the chosen design route.
Evaluated the size and appearance of the prototypes.
03 Production Procedure
Mold Preparation: Cut out the chosen final sketch out of 1/8th plywood to use as reference.
Sculpted both sides of the horse while using the piece of wood to match the shape on both sides.
Made surrounding walls and attached to the base with sculpture in order to pour plastic inside without it leaking to the outside.
Made negative of mold that is going to be casted using the least amount of plastic possible to avoid weight complications when casting out of iron.
Casting:Prepared pattern board with runners, a button, and gates.
Sent the pattern board to Cumberland Foundry and collaborated with the foundry throughout the semester for the casting process.
Hammerforming: Hammered a thin piece of copper into the mold using a rubberhead hammer and air hammer.
Prepared both sides of the weathervane and removed the excess material using sheet metal shears.
Soldering Used a torch in the industrial design metal shop to attach the pieces of the gate with flux and silver into the desired shape.
Sandblasted the finished piece in the Industrial Design woodshop to remove burn marks and achieve a clean, smooth surface finish.
04 Final Ideation
Finalization Installed the weathervane using exterior components, including a cardinal direction cross (N, E, S, W), copper globes, and a mounting system designed to attach the piece to a fence or building structure.
Created branding materials for the weathervane, including a thank-you card and an instruction manual in order to guide the user through installation and care.
Email: kbushnaq@risd.edu Phone: (401) 855-5193
Khaled Bushnaq 2026