When she heard the woman was a slave, Tock was taken aback for a moment, but quickly shrugged it off. The woman didn't look bruised or abused. If she didn't like being a slave, she could just run away, or stab her boss or something. That was what Tock had done back home, except she'd used a frying pan on her Da instead of a knife. And the posh life these slaves seemed to lead was far better than her existence in Sunberth. They were probably grateful to live in such a nice house and be so well fed.
She ate and slept without feeling very impressed with the place. The architecture of the building was more interesting to her than the decoration. Though the soft bed was a rather nice change of pace.
She was eager and ready early in the morning when Valerius brought her down to the smithy. They had everything she needed, and Valerius had bought her more than enough metal, so she dove straight into the work. First it was several hours of setting up the castings.
The smithy had reusable blocks of wax for the first step of preparing the casting. She had to carve out a wax gear in the same size as each piece she would need. This was a long and repetitive process, since she needed multiple copies of each gear. She also wanted to make multiple extras, in case any got ruined during the process.
Each block of wax she carefully measured, etching the shape of her designs onto them. Since many of the gears would be identical, she started with a long rectangular block of wax, cutting out the basic design. She carved out grooves down the length of the wax in the basic shape of the gears, until she had a long block of wax shaped like an unusually long gear. Then she sliced the wax into thin strips, each strip the size of a single gear. She set each piece aside so she could take each piece individually and work out the finer details.
She set the metal in the furnace partway through the time she was carving the wax. It would take a few hours to melt, and she would only need to check on it occasionally during that time. So she used that time to continue carving the wax molds, working each one out as carefully as possible to match her measurements. Since the shopkeepers had their own projects to work on, they had the furnace running all day anyway. She just kept out of their way as she worked on her own project.
Once the wax was carved, she set each piece into sand filled wooden frames. Since the gears were so small, she could fit multiple molds into a single frame. She pressed the wax pieces into the sand, covered them, and pressed down to imprint the molds in place. Once they were all set, the frames were set next the oven to melt the wax and set the molds fully.
The wax melted faster than the metal, and so the molds were ready by the time the metal finished melting. She used large metal tongs to lift the pots of metal one at a time, draining off the slag then carefully pouring the metal into each mold.
It then took a few more hours for the metal to cool. Once the pieces were hardened, she pulled them out of the molds, sorting out which ones were in usable condition. Unfortunately a good number of the pieces ended up misshapen or had small voids in the metal, though this was why she had made more than she needed. The ruined pieces she set aside; they could be melted down again for a future project. The rest, she started working to carefully file down any imperfections that had crept in during the process.
Between the hours spent carving out each wax mold, setting them, melting the metal, and cooling and finishing them, it took the whole day before she was finished. She was covered in sweat and grime, with little bits of wax and sand stuck under her fingernails. Her face was smeared in soot from working he furnace. The fancy clothes Valerius had given her were stained and had a few burn marks. The lace was blackened from soot, and the garment would never be the same.