How does Ray Tomasso create his remarkable cast paper works?

The following series of photographs shows Ray making pulp and
casting one of his pieces in the studio yard.

The process begins in the beater room, where cotton rags and boards
are shredded and weighed.

Scale for weighing rag scrap in Ray Tomasso's beater room.

The material undergoes an initial beating to begin to break the material down into fibers.

The initial beating of the rags begins to reduce them to fiber.

White pulp from cotton ragboard and blue pulp from cotton bluejeans is prepared.

Cotton blue jeans are shredded.

The pulp undergoes a second and final beating in the Hollander.

Cotton blue jeans are pulped in a Hollander beater.

The finished blue and white pulp, ready for casting.

Buckets of blue and white paper pulp are ready for casting.

A sheet casting table is set up in the studio yard, with paper vat, screens and deckles.

A sheet casting table is prepared in the studio yard.

Ray sets framed screens on saw horses to support the paper casting.

Ray sets up a casting surface of framed screens over saw horses.

He then creates a composition of found materials atop the screens.

Ray Tomasso creates a composition of found materials to serve as mold for paper casting.

Linear elements of the composition are created with weighted, taut string.

Linear elements are created by stretching taut string above the collage of found materials.

After the collage is completed,
Ray begins to apply wet sheets of white paper direct from the sheet mould.

Sheets of wet white paper are laid on the surface of the mold.

A third layer of blue paper is applied over two layers of white.

The white paper is covered with a second layer of blue.

The casting process takes a full day.
The finished casting is then dried in place for up to two weeks, using towels to
draw off water and plastic to protect it from the elements.

The materials that formed the mold are then removed from the dry, cast paper.
The paper is glued to a wood frame and fiberglass is used to fill the gaps between
the paper and frame.

Ray then finishes the edge of the piece using a power sander.

Ray Tomasso finishing cast paper piece in studio yard.

The piece then moves onto the next phase, in which it is painted and finished.

final photo © Copyright 2011 Steve MacGregor Photography