Among the more popular awards programs is the “Grammys,” presented annually by the U.S.-based National Academy of Recording Arts and Sciences for outstanding achievement in various categories in the recording industry. But what is generally not known is the process whereby the famous statuettes are created.
Over a period of six months, John Billings handcrafts each and every statuette, which, as most readers know, is in the form of a golden replica of a phonograph (or “gramophone”), complete with cone-shaped megaphone.
Billings, the owner of Billings Awards in Ridgway, Colo., has been making Grammys since the late 1970s. Prior to that, he studied the process as an apprentice under the watchful eye of award design pioneer Robert Graves. Billings grew up two doors down from Graves, a master mold-maker who worked out of his garage making molds for trophy companies. Although stints as a jewelry-maker and dental technician took Billings away from the neighbourhood, he eventually returned to Graves’ studio and became an apprentice.
Billings worked with his mentor until Graves died. Today, Billing’s son Richard is learning the trade.
The Grammy is created using slush-casting, whereby molten metal is poured into a bronze mold until filled. The mold is then inverted, and the metal that remains in liquid form pours out. The time required for this casting operation is sufficient to freeze a metal shell in the mold, corresponding to the inside wall. This process Billings still does by hand. The zinc alloy used for the Grammy is 95% zinc and 5% aluminum; it is supplied by Semco Enterprises of City of Industry, Calif.
After the Grammy is cast, it is plated, first with copper, then nickel, then with 24-karat gold. The base is treated with automotive acrylic urethane paint. The only part of the Grammy that is not cast is the megaphone. Billings must create one from spun brass on a spinning lathe. After an estimated working time of 11 hours per award, the Grammy is deemed complete.
“I’m a perfectionist,” says Billings. “I try to go the extra mile with all the awards I make.”
This is not an exaggeration, for not only does Billings drive out to pick up his zinc supply from Semco; at awards time, he loads up the 250 Grammys in his truck and delivers them personally to the academy in time for the show.
The 43rd annual Grammy Awards will be presented in Los Angeles, Calif., on Feb. 21.
— The preceding is an excerpt from Cominco Metals World, published by Vancouver-based Cominco.
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