From Mud to Mug - how to make good quality stoneware pottery
 

1. First the wet clay is wedged to remove air bubbles and each piece is carefully weighed out to ensure some conformity in the set.
2. Next, the pieces were "pulled" or "thrown" using my hands, a sponge and shaping tools on an electric wheel.  The wet pieces are then cut from the throwing batt and left to dry to a "leather-hard" state so they can be handled.
3. They are then "trimmed" back on the wheel to create footrings - handles and spouts are pulled and attached.
4. Once completely dry the pieces are fired in the kiln in what is called a bisque-fire.  This removes most of the remaining moisture in the clay and leaves the pieces "thirsty" for the next step...glazing.
5. After 9 ½ hours of firing and the same amount of cooling the pieces are removed from the kiln and dipped into a large bucket of glaze slurry.  This slurry is composed of many of the same components as glass.  This firing will create the finish on the pottery piece.
6. Excess glaze is carefully wiped from each piece and the foot rings are washed clean of all glaze.  Any glaze left on a surface that touches the kiln shelf will fuse the piece to the shelf when the glaze melts and then cools...not cool.
7. The glaze firing takes between 11 and 12 hours to complete and peaks at 2190º Fahrenheit.  The temperature is carefully controlled throughout the 4 stages of the firing to ensure complete "vitrification" of the pottery.  This allow the piece to stand up to daily use and abuse.
8. Once cooled (another 10 hours or so) each piece is then removed from the kiln and inspected for faults.  The foot rings of the pieces that pass inspection are then sanded smooth and the pieces are packed, ready to go to their new home.