Marc Zapchenk

The following photos document the process of creating the Bob Dylan Way "Yin Yang Guitars" manhole cover.

The clean graphic style of this design made it necessary to use laser cutting technology for burning the image into particle board. Special thanks to Laser Magic, Inc. for their generous support of this unique project. This truly would not have been possible without their assistance.

Marc safely cuts a 26 inch diameter circle, the size of a standard manhole cover. This board is the prototype that will be used to create the mold for casting the iron.

The laser cut board is now ready to be sealed. Spray painting will help the board release during the mold making process.

The board is painted and ready for beveling.

Marc added clay beveling to the laser cut design to allow it to work with the resin sand mold and iron pouring technique.

Marc made little clay snakes and wrapped them around the type. Then he used a beveling tool to smooth and shape the clay.

The finished positive form is now ready to be pushed into the resin sand (glue and sand) to create the negative impression which becomes the mold.

The resin sand mold was a success and is now being moved on site for the iron pour.

Jeffrey paints a graphite and alcohol wash to prepare the mold for accepting the hot iron.

Notice the crisp clean impression in the resin sand. This would not have been possible without the laser cutting technique that was used to create the board.

This mold is now ready to be merged with the back half of the manhole cover.

Buckets of scrap metal and coke are added to the furnace. The scrap metal included recycled radiators from Split Rock Lighthouse on Lake Superior.

Volunteers carefully poor molten iron at the annual North Shore Iron Pour in Duluth, Minnesota.

It really is as hot as it looks.

No use crying cry over spilled iron

Sand is used to extinguish the fire as the iron pour volunteers hop on top of the form to prevent damage to the casting.

The casting now needs to sit overnight to cool down and cure.

Hooray... it worked! The first two manhole covers for Bob Dylan Way. The Subterranean Homesick Blues themed manhole cover was inspired by Bob Dylan's lyrics and created by Duluth artist, Laurel Sanders.

The finished manhole cover is removed from the mold. The final step before installation will be to clean and grind the casting.

Marc Zapchenk with his Yin Yang Guitars design while on display at The Electric Fetus in downtown Duluth.

Marc poses with the finished cover on installation day - May 24, 2011.

And the covers they are a changin'.

Installed on the sidewalk in front of Fitgers Inn and Brewhouse located at 600 East Superior Street, Duluth, Minnesota

Installed on the sidewalk in front of Fitgers Inn and Brewhouse located at 600 East Superior Street, Duluth, Minnesota