Japanese Handsaws: The Mystery of the Burnt Blade

Everything in life is risk, from the minute you wake up in the morning and stick your tongue into a toaster.

Anon

Introduction

In this article your most humble and obedient servant will present a little-known mystery about traditional Japanese handsaws I call the “Mystery of the Burnt Blade,” as well as a related psychedelic conundrum called “Black Light!”

I will also provide a brief description of how one of the last sawsmiths in the world hand-forges his custom handsaws, and explain how these two mysteries are linked to this ancient, even magical, process.

If you have a metallurgical psychologist’s hat, as I do, perhaps one made of aluminum foil or even brass with attached wires, bells or baubles, now is the time to secure it to your seat of knowledge.

Mysteries

Over the years Gentle Reader and your most humble and obedient servant have grappled with several tool-related enigmas, including such notable head scratchers as: “The Mystery of Steel,” “The Mystery of the Brittle Blade,” and “The Mystery of the Scratched Blade.” You may recall that once we even crossed the center median and swerved drunkenly into the path of an esoteric conundrum called “Supernatural Bevel Angles.” Yeeehaw! That was a close one!

In a world boiling-over with mysteries, however, prioritizing them is sometimes vexingly difficult. For example, is the “Meaning of Life” more important than “Were Bert and Ernie in Love?” Or is the question “When will the Entwives return from shopping at the mall?” weightier than “Are the four surviving Nazgul running just Shat Fransisco or all of Calipornia?”

Cogitating such mysteries has worn my thinking cap down to just a button and a bit of lint, but before I forget (I’m supposed to take some bitter little green pills for my memory, but keep forgetting) I would like to submit for your kind consideration a little-known mystery about traditional Japanese handsaws. As mysteries go, it’s nowhere near as high on the priority list as the whereabouts of the missing Nazguls but nonetheless it still puzzles many. Being exceptionally perspicacious, Gentle Reader may find a worthwhile gem or two hidden among the rubble in this article.

And the story goes something like this.

The Story

The curtain on this mystery doesn’t open on a moonless night, black and ragged as a Chicago politician’s soul, concealing a MacBethan circle of wart-covered witches chanting incantations while stirring a cauldron bubbling over purple flames.

Nor is the scene of this mystery a locked cell in a curiously vacated wing of Gotham’s Metropolitan Correctional Center where the guardsmen all nap cherubically, and security cameras all malfunction magically (perhaps due to a “Nox” spell?), and where a millionaire child nookie bookie has shuffled off his mortal coil by hanging himself with a bedsheet after breaking his own neck. Harry Houdini must be proud!

No, the curtain on this mystery opens of an early evening in Tokyo almost 40 years ago in front of a rickety old wooden building facing a busy street erected in the warm ashes produced by 174 B-29s on the nights of March 9th and 10th 1945 when the city and many souls burned brightly.

Gentle Reader, we find ourselves in front of the shop and residence of a small, pipe-smoking saw sharpener and his family. They live on its second floor, with a workshop on the ground floor adjoining a dirt-floored doma with a single rickety sliding door opening to the street. There’s space in the poorly lighted entry for perhaps three people who don’t despise each other to stand, but no more. The shop space doesn’t have shelves or glass cases, just teetering stacks of newspapers and magazines wrapped in twine crowding in from the walls. The place feels strange and smells of oil and steel filings. I don’t know about you, but it’s an atmosphere I love.

Prior to that time my experience with Japanese handsaws was limited to inexpensive hardware store products with bright shiny blades. I didn’t know much about who made them or how they were made, but they seemed to work OK. On the day of this mystery I was looking for a more specialized saw for ripping 6X6 timbers, one not sold by the average hardware store, so I visited the shop of this professional saw sharpener.

As I opened the rickety wood and glass sliding door and called a greeting the little saw sharpener came out from the back, kneeled seiza-style on the raised floor of his workspace, and smiled like a wood carving of a buddhist saint.

After introductions, I described the job I needed to do, the type of wood I had to cut, and the type of saw I thought would work best. He made a thoughtful face as he sorted through his stock of saws in his mind, bobbed his head decisively once, stood up, and without saying a word went into the back. He returned with a saw blade wrapped in newspaper.

When I unwrapped the blade (no handle) my heart sang as I gazed upon its unadorned, elegant lines and subtle beauty. I could feel the blade quivering with excitement at the prospect of being fed some yummy wood after a boring confinement in the back. It was a 300mm single-edged kataba rip saw with the brand “Nakaya Genji” chiseled into the steel blade.

The saw sharpener told me it was made in Tokyo (yes there were still many sawsmiths living and working in Tokyo back then) by a reputable and skilled blacksmith, but not a famous one, that it was a hand-forged, top-quality working tool, one he had sharpened himself, and that he thought it would satisfy my requirements.

The only problem was cost, about twice what I had budgeted, but pretending I knew what I was doing, I flexed the blade, held it up to the dim light to check the plate for untoward distortions, and the teeth for cavities. I even pressed my palm against them to check their sharpness. After all this posturing I agreed with the saw sharpener that it was a fine blade. With one reservation….

Mysterious Colors

A hozohiki rip saw hand-forged many years ago by Takijiro for your YMHOS

Now, at the time of my visit to the little saw sharpener’s curious shop I didn’t have enough experience or specialized knowledge to ask intelligent questions about the steel and techniques used to forge and tooth the saw, but although I was ignorant, my eyeballs were still not “fushiana” (“knot holes 節穴”), as the saying goes in Japanese, for they noticed something that wasn’t quite right.

What was this smudge on the saw’s face that shocked me but did not faze a professional saw sharpener? It was a localized discoloration at the center of the blade, a vaguely-shaped area golden brown in color, possibly indicative of the blade having been exposed to high temperatures, perhaps hot enough to soften the steel, a serious defect indeed in the case of chisel and plane blades.

The saw sharpener was not impressed in the least with what my knotholes had revealed, but exercising extreme patience, gave me a partial explanation.

As he clarified at the time, and as I was able to confirm in more detail during the intervening years, this area of color is commonly seen on the plates of quality saws made in Western Japan, which included Tokyo where I purchased the saw in question, but it is not commonly seen on saws made in Eastern Japan, which have simple bright steel blades instead. Likewise, inexpensive, mass-produced handsaws, including exchangeable-blade kaeba saws, never have this colorization. Ahah! The thot plickened.

C&S Tools’ hozohiki rip saw hand-forged by Nakaya Takijiro. Please notice the colorization.
C&S Tools’ dozuki crosscut saw hand-forged by Nakaya Takijiro. Please notice the colorization.

So what I deduced from his comment was that this spot of color is neither strange nor suspicious, but is actually desireable, indeed seen as an indicator of quality, depending upon geography. Sound hinky to you? It did to me too.

An Historical Example

Years ago the following example was related to me by a reliable source with personal knowledge, and I while I am extremely fond of daring fashion statements, I have not seen it with my own knotholes and so won’t accept any bets about its veracity that involve a forfeit of wearing lady’s underwear on my head out in public again, so please don’t offer.

From 1639 to 1834 Japan was closed to foreign countries with the sole exception of Holland, and even then access was severely limited.

In the early 1800’s a Dutch doctor purchased a bunch of Japanese woodworking tools which he took back to Holland. Those tools recently returned to Japan and observers noted they had the same appearance as modern handsaws saws made in Eastern Japan, evidence that this colorization is not just a modern feature of Japanese handsaws.

How to Make a Traditional Japanese Handsaw

In order to explain the metallurgical roots of the Mystery of the Burnt Blade I humbly beg Gentle Reader’s kind indulgence as I relate the following summary of the process of making a hand-forged professional-grade handsaw in Eastern Japan as explained to me by Nakaya Takijiro Masayoshi, one for the few remaining master sawsmiths in the world. Any errors are the sole responsibility of your smelly groveling servant.

Takijiro posing in front of his forge.
Takijiro applying a final polish to your humble servants bukkiri gagari saw. Two of his anvils are visible. Please notice the scraper marks and colorization of the blade

Steel Selection

Saw blades do not require high levels of carbon. Indeed, too much will make the teeth fragile. Shirogami Saw steel and Shirogami No.2 steel have been popular for many years, and Takijiro uses S-2, but he prefers Yellow Paper steel with its lower amount of carbon for the extra toughness it affords.

With materials now in hand, let’s get to smithing.

Cutting the Plate

The sawsmith first cuts the steel plates for a run of saws using manual shears. These are not embroidery shears held in one hand, but rather a hand-powered mechanism that sits on the floor with a long blade and plenty of leverage.

Initial Forging

Using a gas/charcoal forge, springhammer, hand hammers, and rectangular steel anvil he then heats and shapes the plates.

At the conclusion of this stage the saw plate is an approximately saw shaped piece of thin steel, burnt in appearance and warped. The iron tang will be attached later by forge-welding.

Nakaya Takijiro forging a saw tang
Nakaya Takijiro’s forge set into the floor of his smithy.

Annealing/Normalization

The next step is to anneal the saw plate. Sometimes this process is called “normalizing.” While it involves heating and cooling the blade, instead of making the steel hard, it makes the steel as soft as possible.

The purpose of this step is to relieve stresses, create a uniform and relaxed crystalline structure in the steel, and to soften the steel to prevent cracking during forging.

Annealing and normalization are very similar processes, both performed by heating the steel to a specific “recrystallization” temperature”(about 750˚C or 1380˚F for Shirogami No. 2), and allowing it to “soak” at that temperature for a specific amount of time. In the case of annealing, the steel is left in an oven and the temperature is slowly reduced in accordance with a specific heat curve, but in the case of normalization, the white-hot steel is removed from the forge/oven and allowed to cool at room temperature, a faster, more economical process.

The traditional Japanese annealing/normalization process Takijiro employs at this stage is technically not pure annealing, but neither is it simple normalization. He heats the blades and upon removing them from the forge immediately places them to soak and slowly cool overnight inside a sealed, but neither airtight nor temperature-controlled, container filled with rice straw ashes, a low-oxygen, high-carbon atmosphere.

This annealing/normalization process is hot and dirty work, unsuited to either the impatient factory worker or to mass-production, one that it adds considerable time and cost to production while yielding few benefits purchasers nowadays can discern using Mark-1 Eyeball, as seen through the lens of what I call “Chinese Logic.

Why Chinese logic, you say? Because the benefits it imparts to the crystalline structure of a steel blade are not only impossible to analyze without using an expensive SEM, but are difficult to check through conventional non-destructive quality control procedures, and impossible to observe in an illustration in a catalog (harking back to the Sears Catalog days) or a digital photo on the internet, all reasons why this critical step is always neglected by other than well-trained, dedicated craftsmen like the blacksmiths C&S Tools works with, who refuse to cut corners.

The next morning, the blades are removed from the container. They are still too hot to handle without gloves or tongs.

Cold-forging

Now that the saw plates are roughly shaped and annealed, the next step is to further refine their crystalline structure by forging them using hammer, tongs and anvil. He does not, however, heat the blades during this step.

At this stage Takijiro prefers to forge blades two at a time, one stacked on top of the other. The position of the blades in the stack is changed frequently so approximately the same number of blows directly strike both faces of both blades. Not only does this save time, but it cushions and better distributes the force of the hammer blows.

He then repeats this process by hammering both sides of a single blade.

The purpose of all this violence is to “tighten up” (shimeru 締める) and improve the crystalline structure of the steel.

Obviously, if this step is performed carelessly or without properly annealing the blades beforehand, they will crack sure as eggses is eggses. Just another of those jobs not suited to the amateur.

Quenching

The purpose of quenching the blade, of course, is to create a rigid, hard, even brittle crystalline structure in the steel.

Quenching Step 1: Heat the blade in a gas/charcoal fire to 800 degrees beginning at the tang end of the blade.

Quenching Step 2: When the blade is properly heated, as judged by eye, plunge it it into rapeseed oil (canola oil is genetically-modified rapeseed oil) cooling it quickly. For more details, please read The Story of a few Steels.

Forge-weld the Tang to the Blade

The next task is to attach the soft iron tang to the hard steel blade by lapping the tang over the blade, heating the lap, and hammering until the two pieces meld. This technique, called “forge welding,” is as old as blacksmithing but has not been standard practice in Japan for the past three or four decades having been entirely replaced by electrical welding.

Takijiro, on the other hand, does not use a welder.

Performance-wise, a forge-welded tang is not superior to an electrically welded one, but since it’s a sure sign of a hand-forged sawblade and indicative of traditional craftsmanship, it’s a detail highly desired by those who know the difference.

A forge-welded tang identified by the curved line crossing the blade just above the “machi” step-down to the tang.

Tempering the Blade

Quenching makes the blade hard, but also brittle and quite useless as-is. The purpose of tempering therefore is to slightly break-down the crystalline structure of the steel while reducing the amount of carbides, thereby making the blade flexible and much tougher.

Proper tempering also greatly improves a blade’s edge-retention performance. This is a key step in the Mystery of Steel, and in the case of Takijiro’s handsaws, is accomplished in four steps.

Tempering Step 1: Heat the blade to 300 °C (570˚F) beginning at the toe (tip) end of the blade, allowing the temperature increase to spread to the tang.

Tempering Step 2: Place the blade on the floor to air-cool.

Tempering Step 3: Reheat the blade to 400˚C (750˚F) beginning at the tang end of the blade, allowing the temperature increase to spread to the toe end.

Tempering Step 4: Place the blade on the floor to air-cool.

The portion of the blade near the forge-welded tang needs to be left a little softer for toughness and to allow the blacksmith to chisel his signature, one reason for the two-step process.

Removing Warpage from the Blade

Subjecting a thin piece of high-carbon steel to extreme violence by fire, hammer, and sudden cooling in oil during the operations described above will always make it warp, so it must next be straightened by the precise use of hammer, tongs and anvil. This is a task that requires patience and much experience.

Adjusting the Thickness and Taper of the Blade.

Two customer ryouba saws, one made in Tokyo and the other Niigata, with handmade handles of larch wood. The colorization is especially dramatic, and although the blacksmiths are different, the color is nearly identical.

The faces of a true high-quality hand-forged saw blade are not tapered willy nilly, nor in the simple flat planes typical of ground and sanded blades. Instead it must be shaped in a “double-taper.” In the case of a kataba (single-edge) saw, the first taper is from the teeth to the blade’s back, meaning the blade is thickest at the teeth, becoming gradually thinner towards the back.

The second taper is the blade becoming thinner from tang to toe.

Combining these two tapers results not in the creation of two flat planes in the saw blade, but curved surfaces on both faces of the sawblade.

Let’s examine this double-tapered surface in a bit more detail. A case in point is the more complicated double-edged ryouba saw. If we examine a cross-sectional cut across a high-quality ryouba sawblade’s width (perpendicular to the long axis of the blade), we will observe that the blade is thinnest at its long center axis and thickens moving outwards towards the teeth on both sides so that, as the blade cuts deeper into the wood, the gap between the blade and hairy sides of the cut increases.

If we next examine a cross-sectional cut through the length of the blade, we will see the plate is thickest at the tang-end and thinnest at the toe, such that as the blade is pulled towards the user, the portion of the blade cutting the kerf is always thinner than the kerf itself, thereby reducing friction and the tendency to bind and buckle. The combination of these two tapers on each face of a sawblade is what your humble servant calls a “double taper.”

Restating the previous paragraph, as result of this double-taper the thickness of the sawblade inside the kerf being cut measurably decreases as a stroke progresses, incrementally reducing the pinching forces acting on the blade in the kerf, as well as the friction acting on the blade produced by hairy fibers. The net result is that the energy necessary to motivate the blade is decreased, cutting precision is improved, and the blade is less likely to be damaged by buckling.

In the case of double-edged ryouba saws, this increase in thickness from the plate’s centerline to the teeth has limited usefulness, however, because, as the blade cuts into the wood deeper than its centerline, the blade gradually becomes thicker increasing friction in the kerf. This is one reason why some craftsmen, including your humble galley slave, prefer single-edged “kataba” saws over the more cost-effective and convenient ryouba saw.

These pinching/ friction forces can also be reduced, of course, by adding extra set to the teeth. But set is not all blue bunnies and fairy farts because, while it’s indeed effective at reducing pinching/friction forces acting on the blade in the direction of the blade’s width, it is not effective in the direction of the blade’s length, unless a large amount of set is added.

Applying minimal set matters because the greater the set, the more wood must be cut, the more time and energy must be expended, and the more cutting precision is impeded. Cheap saws and replaceable-blade saws lacking taper must have a humongous amount of applied set, BTW, an ungainly and wasteful feature despised by knowledgeable craftsmen.

A high-quality handsaw with a good double-taper will cut with less effort, in less time, without binding, and with greater control and precision than a plain, flat saw, even one with adequate set. Contingent, of course, on the skills and perception of the user.

I don’t know where this subtle idea was first developed, but I understand it has been used by advanced blacksmiths throughout the world for centuries. Why? because it works.

So how does the sawsmith impart double taper to a blade? It begins with having a vision of the finished blade in-mind when shaping and forging the blade with fire, hammer and tongs. But there are practical limits to the precision achievable with fire and hammer, so the master sawsmith will adjust the blade’s thickness using two-handed scrapers to shave steel from the plate.

Takijiro’s toolrack of two-handed sen scrapers.
A pile of hardened steel shavings from a saw plate produced by Takijiro’s sen scrapers.

Although few know them and even fewer use them nowadays, scrapers were once tools found in every metal working shop around the world. In trained hands they are capable of achieving amazing precision, such that all metalworkers and even college students studying machinery engineering in the USA as late as the 1960’s were trained extensively in their use.

Expensive 3-axis CNC grinders can do it, but conventional grinding and sanding equipment is unable to achieve the quality of taper that hand-scraping can.

The marks hand scrapers leave on a sawblade are obvious and very different from those left by grinders and sanders, and being the results of handwork, are something to look for when evaluating a saw. On the other hand, ground, sanded and polished blades are shinier and prettier than scraped blades, and if the polishing was done after tapering by hand with a scraper, I can find no fault with it.

But please be aware that extensive sanding and polishing contribute nothing to a saw’s performance, whilw on the other hand are highly effective at concealing grinding failures. Caveat emptor baby.

Cut the Teeth

The sawsmith uses a hand-powered shear contraption with tooth-shaped blades (kinda sorta like the teeth in pinking shears) to cut (or punch) the teeth. The teeth produced during this step are quite rough.

Rough Filing

The sawsmith uses hand files to shape and refine the teeth cut in the previous step.

This first filing operation produces properly-shaped but not perfectly sharpened teeth.

Applying Set

Now that the teeth are properly shaped, the sawsmith applies right-left set to the teeth using an anvil and a special hammer. The following videos YouTube videos show the process, although at a much slower pace than real life.

  • Video 1 鋸のアサリ出し 其の1 準備編
  • Video 2 鋸のアサリ出し其の2 実践編
  • Video 3 鋸のアサリ出し 其の3 最終編

Cutting The Brand Name

The next step in the process is for the sawsmith to use a hammer, anvil and chisel to carve his registered signature into the blade just above the tang, as seen in the photos in this article. This feature was perhaps borrowed from the sword world, but no one knows. In any case, it’s this unique signature and the way it was cut that witnesses the handmade nature of the saw as well as the name of the craftsman that made it.

Sometimes this brand name is easily read, but often the characters are stylized to the point of illegibility. For instance, not only your humble servant, but most Japanese are unable to read even one of the six characters in Takijiro’s signature. “The signature is the signature” he says.

Sharpening

With the teeth shaped and set applied, the teeth are now ready for their final sharpening.

Traditionally, most blacksmiths simplify this step to a quick and dirty sharpening, but for an extra fee, would send the blade to a professional sharpener for a more refined sharpening job called “Honmetate” (hohn/meh/tah/teh 本目立て). Takijiro, however, was trained by his master to a higher level of proficiency, and for the first 3 years of his apprenticeship was tasked with sharpening saws exclusively, skills that are wonderfully obvious in the performance of his saws. All of his saws receive honmetate by him.

I was unable to find a video showing a professional sharpening job on a cabinet-grade saw in-action, only jobs on larger saws, mostly for trimming apple trees. But while the tools and process are much the same, the skill and speed required to sharpen the numerous fine teeth of a dozuki crosscut saw are awe-inspiring.

Video about making a Japanese-style saw vise LINK

The Answer to the Mystery of the Burnt Blade: Colouration (Irozuke 色付け)

In the Japanese language this final step in the saw making process is called “irozuke” (ee/ro/zoo/keh 色付け) which I’ve translated as “colorization.” In the Japanese language this translates directly to “apply color.” It’s also called kesho ( keh/sho) 化粧), which is the same word used for makeup, as in the gunk and powdered pigments women and actors apply to their faces.

In this step, the sawsmith uses a deformed truncated cone, simply a piece of sheet metal bent into a cone with the pointy end cut off and smashed into an oval shape.

He places the wide end of this cone in his forge, or on a gas stove, so the heat will rise and be funneled into an oval shape. He rests the sawblade on the narrower, upper end of the cone so it focuses heat onto a specific area of the blade. When the blade reaches the right temperature, as judged by color changes, he removes the blade and allows it to air-cool.

The answer to the Mystery of the Burnt Blade, therefore, is this “colorization.”

As described above, the first time your humble dogsbody saw a professional-grade handsaw in Tokyo I was shocked at the sight of the golden-brown spot of color on its blade. Since then, I’ve heard many suppositions for its existence, most pungent BS, but the true reasons for this additional step are threefold.

  1. Colorization is the final step in the tempering process, one that slightly softens the steel in a critical spot making the blade tougher. This is one application of “differential hardening” of which blacksmiths are extremely fond, and is important to a saw’s performance.
  2. Second, the resulting differential hardness slightly reduces the blade’s springiness by damping the tendency in a thin hardened-steel plate to develop resonant harmonic vibration, a problem that inflicts many saws. Gentle Reader may have experienced this while using large Western panel saws when the blade tends to vibrate and quickly “waggle” right and left towards the end of the return stroke, movement that is not only distracting but wastes time and can harm precision. This characteristic too is important to those with the skills adequate to tell the difference.
  3. And last, at least in Eastern Japan, colorization is clear evidence that the saw was properly forged without taking any shortcuts, much like an actress will take care in applying her makeup before a performance, except that, unlike bottle and powder makeup, colorization on a sawblade reveals instead of conceals. Oh yes, and it costs a hell of a lot less than Gucci Beauty‘s foundation gunk.
Theatrical makeup tastefully applied to a lady performer at the Beijing Opera. Were a trowel and sandpaper involved or just Photoshop?
Colorization applied to a Japanese Kabuki actor. Obviously a different kind of theater.

The Black Light Mystery

I will conclude by relating another mystery about handsaws Master Nakaya Takijiro shared with me

According to Takijiro, scraping a sawblade by hand can reveal the quality of the forging and heat-treatment of a saw blade in ways no other methodology can, because shavings freshly scraped from an expertly-forged and heat-treated blade will, for a brief few seconds, exhibit a shiny black color, what he calls “black light” (kurobikari 黒光). On the other hand, shavings scraped from an inferior blade will always be plain bright steel.

A grinder is unable to provide this quality insight.

Conclusion

Despite the subject of this article being somewhat obscure, I pray it has has been informative.

Until we meet again, I have the honor to remain,

YMHOS

A cherry blossom lake in Shakujikoen Park in Tokyo

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Permanence

A Huon Pine, native only to the Island of Tasmania

Serit arbores quae alteri seculo prosint – “He that plants trees labours for future generations.”

Caecilius Statius, quoted by Cicero. Motto of John Quincy Adams and his family, among others

This is a guest post by Dr. Antone Martinho-Truswell regarding a highly unusual tree, his adventures working its wood, and his thoughts about permanence. Enjoy.

What Does It Mean to Build Permanence?

Woodworkers – and especially we odder, curmudgeonly, hand tool woodworkers – have a vexed relationship with permanence. 

On the one hand, spend any time reading, listening, or talking to a woodworker of any integrity (not least our distinguished host, Mr. Covington), and you will inevitably hear about building things that last, creating furniture or structures that will outlive the creator. Or else you might hear lamentation of the impermanent, throw-away culture represented by particle board, OSB, melamine, wire nails, and so forth and so on. Stan writes regularly here about building for future generations, about tool chests that preserve and workshop stools that endure. When we chop a mortice or fit a dovetail, the idea is that the end product is permanent – the strength and durability of the outcome justifying the labour-intensive process of creating it

And yet: wood. We are not stonemasons. We are not goldsmiths. We work with a biological material, one subject to biological processes such as mold, rot, borers, gnawing things, weather, sunlight, fire and friction which eat and wear away at wood until it’s gone. Japan’s venerable old wooden structures, record holders across all human construction efforts, pale in age compared to those made of stone. Wood perishes as do all living things (at least since Valinor was sundered from the sphere of the Earth).

This is the story of a permanent wood. A wood as magnificent as it is rare, a wood that is itself a lesson in permanence, and my attempts to make beautiful things for now and the future.

Old and Young Places

I like to think about old things. I was born and grew up in Southern California, where almost everything is new, even the old things. I remember as a child a small water tower near my elementary school, proudly fronted by a sign announcing that it was the oldest building in the area – an august 25 years old. The tower is older now and so am I, but there were old trees around even then. Up north, there are sequoias and redwoods, and of course, the oldest of all, bristlecone pines. I was young then, and didn’t think too much about wood or lumber, but I knew the trees were old. 

As a young man, I moved to England for graduate school, and the world was much older. There was a sense of permanence, in the material things at least: old buildings and old furniture and old books and old wood. Oaken chapel pews and blanket chests and linenfold panelling – the sorts of adornments that, in the USA, are the enviable preserve of grand old institutions in grand old East coast cities, but in the UK, found in all manner of great and humble places. But the trees weren’t so old. England’s ‘green and pleasant land’ is green with farms and fens, but not so much old forest anymore. Like much of Europe, over aeons humans have harvested so much timber that little old-growth forest remains, only secondary growth, coppices and managed woodland. The trees in England are fairly young because the culture is relatively old. I was not yet a woodworker, and I did’nt think much on trees and timber at the time, but I knew the culture was old.

As a married man, I moved to Australia, and here I remain. The prevailing culture – that of the settlers rather than the indigenous people of Australia – is young, and so are the trees. Mostly.

Australia’s frequent natural fires mean that most of the trees that grow here are adapted to grow fast and big, but not long. Generations of forest turn over quickly – in ecological terms that is – with bushfires killing off adult trees and causing their scattered seeds to germinate and grow a generation of newer, younger trees. What’s more, as in America, the brash, youthful settler culture did not have a good track record as stewards of the natural gifts of the island continent, and the few old hardwood forests that once existed have been over-exploited. 

Perhaps with age comes wisdom, but now I am both a father and a woodworker, and I ponder permanence, and wood, a great deal, and what all this youthful forest means for woodworking here in the sunburnt country. 

Hard, Stringy Wood

If you know anything about Australian woods, you know they have a well-deserved reputation for being really, really hard.

The vast majority of our forests and the trees that grow in them are the various and many species of eucalyptus and its near relatives, with two qualities that make them a mixed blessing to woodworkers.

First, they are fast growing, so as to quickly repopulate the land after fire, and second, they are extremely hard – the softest commercially available eucalyptus wood is called “Victorian Ash” (or “Tasmanian Oak” – same wood, different source) in the timber trade with a hardness similar to white oak or rock maple. The hardness of other varieties can easily range up into ipe and ebony territory.

Rainbow Eucalyptus

The result is an abundance of eucalyptus wood great for things like flooring and fenceposts, but fast growth makes it especially stringy, which together with phenomenal hardness makes it difficult to work with handtools. That same Victorian ash, the most common of all hardwoods in commercial use here, is among the best behaved, and a straight grained piece can take a nice glassy finish from a hand-plane, but we have nothing commonly available with the smooth texture of a maple or beech. Victorian ash works like oak at best. The other good furniture eucalypt is Jarrah, which is a lovely orange-brown colour and less splintery than most, but it’s expensive and a good bit harder than maple, so still a challenge. Moreover, it comes from Western Australia, which, along with Victoria, banned all native forestry at the start of 2024, so it is likely to recede to only niche use in the future. 

There are many other beautiful, softer, easier working, and often fragrant Australian hardwoods, but for one reason or another all of them are scarce and hard to track down.

There are few species under plantation production here, and the fast-growing eucalypts crowd out most other species in our forests, so the best cabinetry timbers, like acacias and mahogany relatives, are rare. If you find these timbers for sale, it’s usually from a small-time operation that harvested a fallen tree – so you have to wait around for luck to smile on you. I try to snap up Australian Rosewood priced reasonably. The vast tracts of cabinet timber we once had – the famed Australian Red Cedar, which is actually a mahogany cousin, for example – were all irresponsibly exploited down to commercial extinction decades ago. A permanent culture of wood use requires a forestry industry with an eye toward permanence, which we didn’t have for a long time, and many argue we still don’t – hence the aforementioned bans and the limited selection of commercial wood. 

A few government agencies and private companies are trying to improve sustainable forestry in Australia focusing on Australian blackwood (Acacia melanoxylon). This species should not be confused with the African blackwood of oboe, clarinet and bagpipe fame. Australian blackwood is a dead ringer for Hawaiian koa, and is its closest living relative. It has a rich, deep, brown colour with the same gleaming chatoyancy of koa, but its name comes not from the colour of the seasoned wood, but rather the black color the sap turns sawyers’ hands.

It’s a breathtaking timber deserving of widespread admiration, and one of the few beautiful cabinet timbers down here that weren’t over-exploited to near extinction in the last century. The blackwood timber industry is apparently a bit wiser than their forebears, and so harvests less and charges more to promote sustainability. It’s the nicest timber that can be bought here straightforwardly, and is priced accordingly.

The Ships that Took Our Trees

Clipper Ship, City of Adelaide, 1000 tons

Of particular interest to users of Japanese tools and Japanese woodworking methods and mindsets are softwoods, and this is where Australia is confusing. There are no true pines native to any part of the Southern Hemisphere – but settlers insisted on naming all the fascinating and unusual softwoods down here “pines” – and then importing a northern hemisphere species for most of our plantation wood.

Norfolk Island Pine

Norfolk Island Pine

When Britain established the first penal colony at Sydney in 1787, the site was chosen partly because it was thought to offer a good strategic back-up to the British claims on Norfolk Island – a speck 900 miles out into the Pacific. The trees covering this island – Norfolk Island pines – were thought to be particularly valuable to the Royal Navy, as they tended to produce ramrod-straight single trunks, almost as if replacement masts had been conjured up from the Earth. However, the timber proved too flexible for masts, and the idea was abandoned, though the Norfolk pines got their second act as a popular ornamental plant (including a few all the way back in my home town in California).

Hoop Pine

Much more useful is hoop pine, a near cousin of the norfolk pine that grows on the Australian mainland, and is our only plantation-grown native conifer. I’ve made shoji from hoop pine; it has nice straight grain producing a good shine when hand-planed. The only other commercially available native softwood is Australian white cypress which has a beautiful smell and is famously insect resistant, but unlike most softwoods it’s harder than American oaks. It also doesn’t grow very big, so is mostly used for knotty, sapwood-sapwood edged fence posts, or equally knotty floorboards and decking. I understand that it is not a sustainably managed species, and conservationists often recommend against its use. 

Monterey Pine

The Australian construction industry relies on plantation grown monterey pine (also called radiata or pinus radiata) for all of its general purpose lumber. This is an import from California, now very rare in its natural habitat but grown all over the Southern Hemisphere to compensate for a dearth of native pine species. It is a particular pet-hate of Australian woodworkers, in online forums and general conversation, who lament its often crumbly texture and poor strength. I don’t hate it though – it can take a lovely plane finish and the wide grain does make for beautiful patterns on clear, flat sawn boards.

Huon Pine

Like all Australian trees, huon pine is misnamed. It isn’t a pine at all but rather the only member of its genus – more akin to a cypress than anything else, yet still not a cypress, a thing of its own. 

Fans of Tolkien’s works may lament that its name is Huon and not Huorn, but no tree was ever more deserving of association with Tolkien’s tree-herding Ents, that ancient race of sentient defenders of the forest.

Huon pines grow only in Tasmania, and only in the wet and mountainous western regions protected from fires. Provided they have that protection, they may achieve something most Australian trees do not – great age. Huon pines grow incredibly slowly, barely thickening as century after century wash over them, living at least 2000-3000 years, with some thought to be even older. This is best evidenced in the astonishing tightness of their annual growth rings. It is not uncommon to see specimens with annual growth less than half a millimetre – or to put it another way, the trees gain less than two inches of trunk radius per century. While immensely slow, these trees can still grow immensely large when given that precious critical thing – time. They are probably the longest-lived trees in the Southern hemisphere, and certainly in Australia.

There are lots of small huon pines growing now, though few big ones. They should be huge, but they are not, because the great ones were all mostly cut down to build boats – a vast fleet of huon pine watercraft were constructed in Tasmania, using up most of the big trees. The promise of the perfect tree for shipbuilding that had fallen flat on Norfolk Island paid off big time in Tasmania with the huon pine. The reason for the single-minded use of these ancient trees for shipbuilding will become obvious, but as a result of this hasty zeal, they are now the single most protected species of tree in Australia, both to allow the forest, with Ent-like patience, to recover, and to preserve the few very old and very large specimens that remain. 

Beyond the Grey Rain-curtain

These trees are old, though their lives are but the beginning, and death, as Gandalf once taught young Peregrin Took before a fateful battle, is just another path beyond which the journey does not end. This is, cynically, true of all wood that gets put to human purpose, but it is true in a special way for huon pines because of a unique chemical in their wood. Not unlike other fragrant cypress-like softwoods – including Japanese hinoki – huon pines contain great amounts of oil, in this case, an oil called methyl eugenol that protects them from insects and other wood-hungry nasties. Methyl eugenol is, as it happens, the ticket to eternity for wood. 

For whatever reason, methyl eugenol, in the very high concentrations in which it is found in huon pine, is astonishingly successful at preserving timber. Huon pine timber is highly prized for shipbuilding because it’s easy to bend and work, completely impervious to insects and fungus, and readily survives the rigors of the aquatic environment. All that ever seems to happen to huon pine is that the surface turns grey in the sun – much like teak. And then it simply endures. 

And I mean it endures. The 3,000-year age of living huon pines is one thing, but researchers have found fallen huon pine logs on the floor of the forest that have lain there, unmolested by decay, for as much as 38,000 years! Not petrified, not fossilized, just oily wood under a weathered surface, simply enduring. 

These characteristics are also why we still have a bit of precious huon pine timber available nowadays, reclaimed from time to time from old boats and old furniture, as durable and enduring as ever. Moreover, the foresight that was missing when the trees were mostly cut down a century ago was not blind when hydroelectric dams came to Tasmania. In the 1970s, with two valleys set to be flooded, the Tasmanian government allowed loggers to go into the valleys and cut down the pines – but not to take them. The loggers, working in tall boots even as the dam waters were rising, would leave the logs where they fell, to float up to the surface of the new lake as the waters rose. 

That was 50 years ago – the logs are still there, floating on the lake. The outer layer turns grey to about 1-2mm in, and then, inside, the creamy golden wood, as perfect as the day it was felled, endures. The decades afloat harms it not at all, and every year a tiny portion is licensed to be taken for restoration and preservation jobs.

This is all the unreclaimed huon pine that there is or ever will be for woodworkers to use, and they estimate they have about 50 years’ worth left at current extraction rates. But with the wood so impervious and eternal, what is already in cabinets and drawers and tables and ships will continue to circulate and be reused. It is a wood with true permanence.

An Unexpected Responsibility

At this point I will enter the story to share the most harrowing and rewarding of my experiences as a woodworker.

By chance, I had the opportunity to acquire three large slabs of huon pine, cut and dried in ages past but never used. Compared to the tiny crafting boards and turning blanks that are generally available (at great price), this was a bit of a windfall. I could have, with all cynicism, listed each one for sale for several hundred dollars, pocketed the profits, and went on to buy more quotidian woods. I did not do this for two reasons.

First, and perhaps most pointedly, with visions of epoxy pours and hairpin legs plaguing my dreams, I was overcome with a sense of responsibility to “protect” this precious wood – whatever that means. I wish to acknowledge, in self-reflection and humility, that I am an amateur woodworker. A reasonably experienced and meticulous one – but an amateur nonetheless, albeit one who works with hand tools and has the hand tool mindset. My work is fine but not perfect. But I suppose I like to think that the tool marks I leave here and there, occasional tear-out, and other mistakes that remain have a certain honesty and worthiness to them, becoming of a slab of great age. Vanity of vanities, all is vanity…

More than that though, I saw in these slabs of huon pine, and in the legends of these trees, an opportunity for permanence. Here were three great hulking slabs of a tree older than the nation-state it was felled in (I counted 800 growth rings on one of the slabs – and it wasn’t even a centre slab), thick and strong, and made of the closest wood comes to being an imperishable material. Here was the opportunity, if it was ever going to exist, for a piece of furniture that might outlive the memory of my name. 

It had to be a table. Only a table could use to best effect the wide expanses of precious wood – laying them out on full display for all who saw them to admire. No matter how perfectly I might make a cabinet or chest, it would not do justice to the material. And, as history, archaeology, and literature show, only a table is so intimately connected to life and family and holiness by its proximity to hungry mouths, little hands, and eager minds as they first do their colouring and then their maths homework, and then their college applications. Only a table is ever so truly loved by generations as to be worthy of wood older than all those generations combined. I simply couldn’t bear cutting the beautiful slabs into small pieces. So for months I fretted; and worried; and stressed about the crushing responsibility of making the first cuts. 

The Weight of History

I am an apartment woodworker. My family home is a house in the mountains west of Sydney, but I work as Dean of a university college and we live most of the time in the Dean’s residence, an apartment on campus. I am blessed with a very patient and indulgent wife and an apartment that happens to have a sort of wide corridor I use as a tiny woodshop. Space is still limited, though, and I try not to stockpile wood (in the interest of stockpiling tools – ahem). So, three slabs, two metres long and the best part of a metre wide, mocked me each time I had to shuffle past them. And still, I fretted. 

I eventually decided upon a refectory table so that no matter how many chairs are crammed around it, none clash with the legs. And with a strong stretcher tusk-tenoned into each leg to allow it to knock down, so that I could make it big but still fit it through doorways. Most importantly, I needed to keep the two 800mm wide boards that made the tabletop flat – so sliding dovetails across the bottom to counteract any cupping. And those sliding dovetails would be a perfect place to pin the top to the legs, with removable dowels, again so it could be knocked down to move. Drawbored mortise and tenon joints to hold the I-shaped legs together without glue (since all that wonderful oil makes gluing troublesome anyway). A kanna-shiage (handplane finished) top for beauty and touch, with just a light coat of oil and hard wax, so that the wood itself can be appreciated. A magnificent vision. Complex and well-chosen joinery. Perfection worthy of the tree. Entirely beyond my experience or skills…

I had to start by getting to know the wood. Before any cutting or marking or anything, I realized I could not confront the massive task I had set myself without first knowing what it was to get huon pine under saw and plane, to see, feel it, and smell it.

.

 

I hoisted one of the slabs onto my sawhorses, and with a few strokes of the little aogami roughing plane on the left, and a few more of the shirogami finishing plane on the right, I had my first look at the slab, and my first curls of huon pine shavings. (No, Stan, I don’t London finish my plane bodies. They are dirty, it’s patina.)

The smell – oh the smell. The smell of huon pine is unlike anything I have ever experienced. It is sweet and rich and almost creamy, but without even a hint of sugariness or caramel, nor any of the medicinal notes of cedars or cypress. I suppose the aroma is a little like gardenia flowers, but different. And it’s persistent. I saved bags of little offcuts that are no less fragrant now than a year ago. 

The scent was such that I almost did not notice the figure at first. From some angles, nothing more than a very tightly grained, golden softwood, with rippling grain caused by the irregular growth of the tree’s surface over the centuries is visible. But when the light strikes the surface of the top at the right angle, a shimmering sea of lamellar rays cutting across the grain pop out, almost obscuring the grain with its gleam. Beautiful but subtle – much like the scent. This image and this aroma is now linked with permanence in my senses.

With the feel, smell and appearance of the wood now embedded in my mind I began to feel more confident about beginning my table project. One serious concern remained, however, namely: tear-out.

Layout That Fills the Workshop

I started in with trepidation, hoisting the two closest matched slabs onto my horses and getting to work. In my little shop, I have no room for a great big assembly table, so the slab was my workbench, and took up the whole shop. Here you can see my cramped little shop, replete with little atedai against the wall, assorted tat taped and hung on the walls (including my Palm Sunday palm, awaiting the coming Ash Wednesday), my tool chest brusquely stolen from Stan’s design, and a lovely old tansu filled with bric-a-brac.

Layout was painstaking, although not because the joinery was especially complex. Before shaping, the two “I” shaped legs were six simple boards and the stretcher would resemble nothing so much as a 2×4. The only complexity to the initial layout arose from the graceful radius I had planned for the long edges of the two top slabs. I could have cut them with straight edges and cut the curved edges later but that problem would have been unnecessarily wasteful. 

One simply cannot waste this wood. If you have any respect or regard for the trees that support our craft, it repulses the conscience to even put plane shavings into shop bins. Moreover, I absolutely refused to cut these slabs in anything but the most efficient, offcut-preserving way. As a result, layout took days (or, rather, nights. Amateur, remember?).

The two surfaces of the slabs I used for the top each had unique flaws and virtues. In the end, curving the tabletop’s edges to accommodate the natural edges and features of the slabs proved effective in maximizing the tabletop’s size while minimizing waste of this rare and valuable wood. For example, in the photo above you can see where the near right corner of the slab narrows towards the end, an inconsistency my layout had to accommodate. This layout was also necessary because two of the slabs were contiguous in the bole and one was not, such that the two contiguous, matched slabs had to be used for the top even though one was somewhat larger than the other.

Dealing with the constraints that imposed this layout taught me important lessons in collaborating and compromising with the wood. In line with Japanese tradition, I knew I wanted the “outside” surface of the board to be oriented upwards in the table, and so my layout prioritized that side. As a result, both slabs ended up with prominent natural flaws on the underside – like greyed areas, bark incursions, and even one gash that looked as though the tree had been struck with a red hot poker.

There is a school of thought in modern, machine assisted, YouTube recorded woodworking that cannot tolerate such defects, no matter how small or natural, in any piece of furniture, demanding they be either removed entirely or filled with colored epoxy. The first approach I reject because wood is natural and I believe it should feel natural. I enjoy the fragrance of the wood, and the feel of running my hand along the underside of the table, sensing the evidence of the tree’s story, together with the tool marks I intentionally left. The latter approach I reject because epoxy is plastic, and I work with wood. The table bears the scars it earned in life, but only reveals them to those with enough appreciation and humility to get down on their hands and knees to gaze upon them. 

Putting Blade to Wood   

I do not now, and suspect I never will, own a table saw. Someday I might own a bandsaw, but I’m not convinced. In any case, I won’t have any of these things in the house whilst my daughters are young, as much to spare my family’s lungs from dust as to avoid injuries, however unlikely. 

So that meant I had to figure out a way to accurately break down these slabs along my layout lines with hand saws, in a room that barely contained the slabs. 

I couldn’t do it on the sawhorses – that would require me to stand on the slabs to make the long rip cuts, which seemed risky to their integrity without a supporting table underneath, especially when sawing the narrower pieces. And the slabs were too long and too heavy to comfortably use the Japanese low horse and foot-clamp method, which I am normally fond of for long rips.

The solution I selected was to support the slabs horizontally on one long edge using my 6-inch thick planing beam, with the other long edge supported on low horses with extra boards taped to them to make up the difference in height. This provided enough vertical clearance under the slab for a kataba saw. This arrangement had other advantages too. As I ripped from one end of the slab to the other, I could stand on the slab directly above the supporting planing beam, which was in turn resting on the floor, preventing the slab from shifting position while avoiding downward deflection of the ever-narrowing slabs.

My back did not love this hunched sawing position, but it was more comfortable than you might expect, and in two long sessions of rip-sawing, I had everything broken down to pieces: two wide top planks, each tapered on one edge, two vertical leg pieces, four feet and aprons for the I-shaped legs, and one long stretcher. As it happened (and as you can see below) the offcut from the third slab was almost a perfect extra stretcher. I still have it and will use it for something someday. It is the world’s most magnificent (and I suspect valuable) pine 2×4. The two venerable katabas, one rip and one crosscut, may be seen taking a well-deserved rest after rendering magnificent service. 

With designing, planning, layout and rough cutting done the project shifted to the shaping and joining phase requiring greater attention, so I put down the camera, and did not pick it up again until the job was done. Sadly, I don’t have photos of gorgeous shavings rippling off planes, or of the massive Anaya-nomi I used to cut the mortises for the stretcher to pass through the legs, or of the nakin-kanna rounding off edges. 

This work was more-or-less conventional furniture-making; taking the neatly rectangular pieces of wood I made in the rip-fest above and shaping them into components using good steel and keen eye. I didn’t follow a borrowed or historic pattern for any of this, but worked out my own take on the refectory style of dining table with two I-shaped legs and a single stretcher.

I made a pattern of a single asymmetric curve using a bit of sturdy brown paper shopping bag, leaving the carry handle attached to hang it on my shop wall throughout the process so it was always to hand. I used this same curved pattern throughout to define all the curves in the project, starting with the concave slope from the mortise in the feet to their toes, the tapers from centre to ends on the vertical legs, and again as the most important curve in the project – the gentle swell of the tabletop’s long edges from one end to the middle and then tapering back to the opposite end again. 

Once the base was completed, the conventional woodworking ended and the real gauntlet began – the top. 

The top was made with the two long, wide boards shown with my kataba saws in the photo above. At almost 400mm wide each, they were a challenge to handle, a bigger challenge to plane, and an even bigger challenge to keep flat. 

The work of planing the wood went alright. The swirly grain of huon pine is not terribly prone to tearout, and like all quality softwoods, is a joy to plane in the direction to which it agrees, producing shimmery, breathtaking surfaces. The trouble is that each 400mm board contained 800 years of growth rings with grain direction changing within each board many times due to storms, cool summers, and a lightning strike or two as empires rose and fell. And with such tight grain an entire century of growth, along with the changes in the tree’s environment that impacted that growth, ended up recorded within a mere five centimetres of width – narrower than the thickness of a standard 70mm kanna – and often without apparent visual clues. As a result, seemingly neat, fine ribbons of shavings pulled end to end would be followed by tiny but significant tearout here and there across the board. 

Reader, this took days – days of sharpening by very best white #1, fine mouthed, perfectly (amateur-perfect, mind you) tuned kanna. Days of shaving just exactly to this specific point, in just this direction, just so, to clear up a spot of tear out, then switching sides and going the other way, hoping and praying and watching that I didn’t overstep the boundary and have to start over – which I did, many times. And all the while, awkwardly walking around the massive slab, leaning over it to plane the far side, getting half up onto it like a billiards player, and then doing it all over again on the other slab. There is still some tear out in the surface, especially around the teardrop-shaped bark inclusion that gracefully adorns one corner of the tabletop. But it’s pretty close.

Keeping it Flat

An important aspect of the project was ensuring the wide, solid-wood tabletop remained permanently flat through changes in temperature, humidity, loading and coverings. In the case of such wide slabs, there was only one realistic solution – sliding dovetailed battens on the underside. This design detail had the advantage of providing two level, perpendicular surfaces to connect the legs to the tabletop.

Of course, a hard cross-grain connection between the battens and the tabletop using glue and screws would end in tears after just a few years, so I cut two blind sliding dovetail slots in each half of the tabletop beginning at centre joint of the toward to about 8-10cm of the edges, then cut dovetails into the battens to fit. The two planks hold the battens captive between them once installed, and the friction in the sliding dovetails locks the two slabs together without glue, dowels or hardware.

To use glue anywhere in this project seemed wrong. In any case, the oils in huon pine don’t play nicely with glue, and the joinery connections were the better plan. 

I cut the dovetails in the battens and tabletop planks using my cleverest of all Japanese planes – the male and female dovetail plane, a rare beast indeed.

With the battens installed I cut 10cm wide shallow bevels on all four lower edges of the top, tapering the top to create the illusion of a tabletop only 20mm thick from a slab about 40mm thick in the centre. This involved a lot of plane work.

I left the underside a bit more rustic, even allowing large areas of “live” bark to remain as a lagniappe to the worshipful person who surveys the underside. You might think that leaving bark on the underside meant that I contravened the usual practice of Japanese woodworkers of using the outside surface of a plank as the show surface, but no – though not Japanese, I cleave to this principle invariably, but in this case, the history of the tree involved so many twists and turns that the bark inclusion was exposed on the inner surface of the board.

For clarity, allow me to explain what may not be obvious from the photos. The two legs are connected by mortise and tenon joints to horizontal feet at their lower ends and horizontal beams at their upper ends. In turn, the trestle leg beams are connected to the two battens by four dowels, two at each batten, that pass through the beams and battens at an upwards angle. After exiting the batten, the end of each dowel presses tightly against the underside of the tabletop, slightly bending and binding it in place. 

To disassemble the table in preparation for relocating it to our home in the mountains outside Sydney, I just need to knock out these four dowels and slide the battens out of their dovetail slots, and knock out the two wedges in the ends of the tusk tenons securing the spreader beam connecting the legs. This design has worked well, and the dowels are strong enough that the table can be lifted and carried by the top alone.

The Finish

Now, a great part of me wanted to leave the wood unfinished, both to enjoy the raw kanna-shiage surface, and to ensure the magnificent smell would not be diminished. But, to provide some protection and give a bit of extra visibility to the lovely grain, I gave the wood a couple of coats of thinned pure natural tung oil, and then rubbed on and buffed out several coats of carnauba wax creating a surface hard enough to help protect the relatively soft wood from dings and scratches. Also, my wife liked the colour better oiled than unfinished, a very important consideration for all of my woodworking efforts.

And that was the job done, and here it is, in its home on the covered veranda of my house:

As you can see, the finish turned the feet, which I cut from a discontiguous slab, a darker color than the rest of the table, but it’s an effect I rather like. The clouded figure of the top shimmers beautifully in the morning light from the East, and the little imperfections quietly witness to handwork, something for me to fret over in my quietude at meals around the table. The horizontal beams at the top of each leg that mate with the battens, not visible in the photos, are identical to the feet, except of course inverted.

I do not think I am testing the permanent nature of this table by using it outdoors  – though I may move it inside for a different practical reason: it is now the largest table we have, and has already made a couple of trips inside for big family gatherings. Rather, faced with a true forever wood that can endure against the elements, it seems only right that it should experience them and demonstrate its aplomb. I am glad in the end that I did not glue the centre joint of the top surface because it allows the two slabs to move and stretch a bit on humid days without cracking or busting the seam, and while this does mean they become un-flush for a day or two, they settle back in becoming flush once again when the weather dries out. The table can breathe. 

I will inevitably make little corrections as the table and I get used to each other. I remain unsatisfied with the very rectangular shape of the stretcher, and when the time comes to break down and refinish the table I will add some curvature to the stretcher. I will also probably resurface the top perhaps once a decade, as it ages and my skill with a kanna (hopefully) improves. Part of the joy of using a wood that should outlive my bloodline to make a table of great permanence that can be disassembled and reassembled as needed is the anticipation of ongoing minor improvements, and the relationship I and future generations will have with it. 

In the end, I still do not quite deserve this wood, because no one does. It is right and just that the Tasmanian government has banned the felling of any more of these trees, and it is right and just that the remaining wood is hard to come by and cherished. I am happy for the opportunity to make something permanent with this magnificently permanent and beautiful material. 

Antone Martinho-Truswell is a professional zoologist and amateur woodworker. His work can be found on Instagram at @stjosephwoodworks, where he posts his projects, experiments, and failures, and takes the odd commission. If you enjoy his writing and want to learn more about his day job, his book, The Parrot in the Mirror, is available from booksellers online and worldwide.

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In The Blood

Make of yourself an honest man, and there will be one less rascal in the world.

Thomas Carlyle 1803 – 1855

It behooves a man to know human nature in general and his own nature in particular, at least in your humble servant’s opinion, which, along with $1.25, will buy a soft drink in a can.

Has Gentle Reader ever wondered why people do some of the things they do? While it makes perfect sense to work diligently for the necessities of life such as food, clothing, and housing, we do many unnecessary things that yield no apparent profit, for example gardening, despite fruits, vegetables and even flowers being easier and cheaper to purchase in a grocery store. And how about the large, lush green lawns and ornamental plants and trees we install around around our homes and maintain at great effort and expense, plants that serve no practical purpose but cost us time and money and other resources?

What whips drives us to these excesses?

I daresay this isn’t just a guy thing, either. Many ladies insist on weaving, knitting, and sewing clothing and home furnishings by hand even when mass-produced, inexpensive products of similar quality and utility can be readily purchased from stores anywhere. It just doesn’t make sense, and I say that as a husband who, at the behest of She Who Must be Obeyed, has spent thousands of dollars on CNC sewing machines with unobtanium armatures and smoothie attachments all to make quilts that never spend a second on a bed and seldom even see the light of day.

What is this madness that has her gripped in its barbed talons?

But I fear the madness runs deeper still, for many males of the species spend inordinate amounts of time and money buying trucks, ATVs, clothing that makes them look like trees, camping gear and weapons of death and destruction (aka WODADs) in preparation for hunting season, a time when otherwise sane people don orange costumes and chase Bambi around the mountains and forests just to obtain the most expensive meat to be found anywhere in the world. It’s just nuts.

And don’t even get me started about fishing. A good time was had by all during these hunting and fishing expeditions, but the financial benefits are impossible to calculate. It just isn’t logical…

Woodworking is useful for making housing and furniture and many of the tools essential to civilization, but what about woodworking as a hobby? Isn’t it quicker, easier, less expensive and more sliver-free to buy pre-fabricated houses assembled on-site with bolts and furniture made of MDF, plastic and steel excreted by Chinese factories? Of course it is, so what is this friking parasite madly manipulating levers in our brains compelling us to make these things with our own hands instead?!

I don’t know why these urges drive us so relentlessly. I only know we want to do them and that doing them gives us satisfaction. But I do have a humble theory I will present for Gentle Reader’s consideration, just for giggles.

I believe that the habits and actions that successfully preserved our ancestors long enough for them to produce and raise each generation of humans became imprinted in each subsequent generation’s DNA.

Successful farmers who survived in ancient times passed particular genes on to their descendants. I suspect it is the farmer gene that compels so many of us to grow fruits and vegetable and surround our homes and cities with lawns and plants, a form of agriculture similar to that which kept our ancestors from starvation. It’s the only possible explanation for the universal compulsion to plant stuff.

The children of women who spun, wove, knitted and sewed clothing and bedding survived cold winters inheriting the sewing gene. I’m not sure where smoothie attachments fit into the equation, but clearly sewing machines have become part of the compulsion in modern times, possible evidence that behaviors evolve.

The children of successful hunters and fishermen survived too. The compulsion to perform these activities is still strong in many, your humble servant included. I’m sure you’ll agree that the ritual of talking around the evening camp fire about the big one that got away while saber tooth tigers and cave bears prowled in the shadows beyond the light of the communal fire is much much older than recorded history.

Somewhere not far out on a limb of Gentle Reader’s family tree are hundreds, perhaps thousands of ancestors that shaped trees to make houses to protect and keep their families warm, and beds, tables, benches and chests to make life cleaner and more pleasant. This is a healthy and noble urge, one that, like farming, sewing, hunting and fishing has been useful in keeping body and soul in intimate contact for many thousands of generations in humanity’s past.

My father inherited the woodworking gene from a carpenter ancestor, one of two brothers that left England in the 1600’s to travel to South Carolina by leaky boat. It appears I in turn have passed it down to my sons and grandsons. I am glad of this for mayhap I hear the toenails of wolves clicking on stones in the dark shadows outside the firelight just now, so a solid door of thick hewn oak with a sturdy cross-bar may come in handy before the morning.

But for now, please ignore the snuffling and scratching noises at the door, pull up a chair by the fire and let’s get started on that chess game, shall we?

YMHOS

Waiting for dark, and dinner to walk out through that confounded wooden door.

If you have questions or would like to learn more about our tools, please click the see the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

Please share your insights and comments with everyone by using the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, or thuggish Twitter and so won’t sell, share, or profitably “misplace” your information. If I lie may my riding lawnmower lose power as I pass between two ready-mix concrete trucks on the Tomei Highway. Eeeehah!

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Japanese Handsaws: The Twins

The Ripsaw member of the Twins. Notice the curved back peaking towards the far corner, the golden temper discoloration typical of handsaws made in Eastern Japan, and the old-fashioned forge-welded iron tang. With a toothline length of 330mm and progressive teeth (smaller towards the tang), this is a serious saw for serious work.

Communism is the opiate of intellectuals [with] no cure except as a guillotine might be called a cure for dandruff.

Clare Boothe Luce

his article is a show-and-tell about a matched set of custom-forged handsaws which have been your most humble and obedient servant’s trustworthy companions in the noble profession of making sawdust for many years.

A Bit of History

The archaeological record suggests that, at least in areas of the world where rusty remains have been excavated, the standard metal handsaw in ancient times had rip teeth only. As evidenced by the superior mental powers Gentle Reader exhibits, Woodworkers have historically been extremely intelligent people, so no doubt many sawyers, carpenters and joiners back in the mists of time independently discovered that filing (or stoning) their sawteeth to an acute bevel angle and alternating the direction of the bevel made the saw cut much faster and with less effort across the grain (i.e. crosscutting).

With this discovery, the crosscut saw was born, and thenceforth has been a worthy servant to its masters and a good companion to its elder sister the rip saw.

In modern times with the proliferation of inexpensive (and dangerous) circular saws, rip handsaws have become as rare as selfless tax collectors, but the combination of a rip saw for making cuts parallel with the direction of the grain of the wood, and a crosscut saw for making cuts perpendicular to the grain of the wood has been common-sense among those who value accuracy and efficiency at least since the proliferation of carbon steel saws.

The Twins

Some decades ago while working as a carpenter, your humble servant realized he needed a set of larger rip and crosscut saws for fabricating joints in timbers. The search resulted in the purchase of several saws, but the set described in this article are the two I have come to rely upon for such tasks most.

Both saws were hand-forged 70~80 years ago in Sanjo, Japan by a saw blacksmith named Azuma with the brand-name of Nakaya Choujiro (中屋長次郎), a venerable name in Eastern Japan. The grandson of this blacksmith is still producing saws in Sanjo today, including the Seijiro brand ryouba saws we carry. Nowadays nearly all of his production has shifted to short saws used by luthiers.

I found these saws in a tool store in Tokyo which is now defunct due to the owner’s inconvenient relocation to the big lumberyard in the sky. At the time of purchase, the store owner informed me they were originally commissioned by, and custom forged for, a Miyadaiku (temple carpenter) in Arakawa Ward of Tokyo who had moved on to sorting boards in a more exalted clime without picking up these sawblades (no handles), leaving them sad and lonely in a cabinet hidden behind buckets of paint and roofing materials.

I get misty remembering their joy at being rescued after languishing so many years in darkness…

The Rip Twin aka Bukkiri Gagari

The saw in the photograph above and at the top of this article is a large kataba (single-blade) rip saw with aggressive, progressive-configured teeth called a “bukkiri gagari.”

“Bukkiri gagari” is a name used for large rip saws with this style of handle. The word “gagari“ refers to a large rip saw. The word “ bukkiri” probably means “chopped” or “cut down,” referring to the shortened tang.

The pointed tang, typical of handsaws intended to be fitted with a straight in-line handle, was bobbed at the time the saw was forged, evidence that it is not a conversion, but was intended to be a bukkiri gagari when just a twinkle in Grandfather Choujiro’s eye.

The large brownish-orange discoloration seen on the blade is neither corrosion nor a shadow due to poor lighting, but a remnant of the heat-treating process common to saws forged in Eastern Japan, more evidence of quality handwork.

The blade’s length measured from tip to the beginning of the tang is 425mm (16-5/8″). The cutting edge (teeth) measures 330mm (13″), making it a 1-shaku 1-sun blade a slightly unusual length. The blade’s overall length measured from the tip of the exposed tang to the tip of the blade is 625mm (24-5/8″). It measures 130mm (5-1/8″) at the widest point at the tip of the blade. The back of the blade has a slight curvature away from the cutting edge as is standard for larger rip saws forged in Eastern Japan.

A closeup of the tang of the bukkiri gagari member of the team. Sorry for the poor focus, but the hand-carved signature of Nakaya Choujirou (中屋長次郎) is plain to see. Some people prefer to jamb the handle on permanently, while I prefer the options a wedged handle provides. The wedge can be inserted from front or back, top or bottom, changing the angle of the handle and its distance from the cutting edge. The forge-welded connection between iron tang and steel handle is more visible in this photo. This detail is coveted by aficionados of Japanese saws as witness of quality handwork.

I made the handle from Japanese White Oak stained mahogany color. It measures L270mm x w38mm x t30 (10-5/8″ x 1-1/2″ x 1-3/16″).

No doubt Gentle Reader is familiar with the more common Japanese handsaws with straight, softwood handles. This style of handle is called a “shumoku tsuka” 撞木柄 (shoe/moh/ku/tsu/kah) and is attached to the blade’s tang at an angle.

A shumoku is a wooden mallet used to strike bells in the Buddhist religion. I don’t know why this word is used for a saw handle; No one I have asked has been able to provide useful insight.

The shumoku handle can be attached to most any Japanese sawblade with a straight tang. It has several advantages. First, compared to the standard long handle attached in-line with the tang, it makes the saw much shorter in length and therefore handier for working in tight spots. This is especially useful when making vertical cuts from below for joints in the ends of large timbers resting on sawhorses or during erection where a long handle would get in the way.

The second advantage of the shumoku handle is the fact that, when combined with the stiffer blades of large rip saws, the user is better able to bring the stronger muscles of legs, back and both shoulders into play for more powerful cuts, an ergonomic principle similar to the thumbhole handle once common in Western handsaws.

The stance this handle makes possible also provides more leverage (greater moment couple) when cutting in tight situations and at unusual angles than a longer, straight handle can. This last factor makes the bukkiri gagari saw most valuable IMHO.

The Crosscut Twin

This is the crosscut member of the Twins. Also made by Choujiro with a forge-welded tang, it was forged back in the day as a matched set, and like it’s rip sister, it’s “juissun” in length with a toothline of 330mm (13″) long. The teeth are not progressive. Notice the curvature to the back which is the approximate inverse of the curvature of its twin the bukkiri gagari saw shown above. Subtly beautiful.

The crosscut member of this dynamic duo is also a kataba 片刃(single-edge) saw with a custom-made but more ordinary straight handle.

It’s overall length is 845mm (33-1/4″), with 420mm (16-9/16″) of that being the blade extending past the handle. The blade is 125mm (4-15/16″) wide at the tip.

The cutting edge portion of the blade matches its companion at 330mm (13″), so it too is a “Juissun” saw, meaning 11 sun.

It too has a beautiful curvature to its back which in this case is directed towards the cutting edge instead, giving it a diligent posture. As is the case with all matched sets forged by the same blacksmith (at least in Eastern Japan) the curvature of the back of each saw is the inverse of its partner so that they nest neatly against each other all lovey dovey. Although these cosmetic details have little if any practical purpose, Japanese shokunin are unreasonably fond of these matched saws, as am I.

Of course, the handle is approximately the same length as the the blade (not including the tang), and oval in cross section measuring 30 x 35mm x 425mm (1-3/16″ X 1-3/16″ X 16-3/4″). We will discuss how to make this type of handle in a future article.

Your humble servant made this handle long ago from a piece of scrap Akita Sugi cedar (cryptomeria), wrapped it tightly with copper wire at the mouth end to reinforce against splitting, applied a dab of solder to lock the wire in-place, and finished it by rubbing the wood with a tool called an “uzukuri” made from skinny but hard plant roots to partially remove the softer summer wood leaving an excellent, textured surface that won’t slip no mater how wet with sweat it becomes. I love Akita Sugi.

Gentler Reader (may the hair on your toes ever grow long!) may be wondering why one would use a short, sideways handle for a rip saw but a long straight handle for a crosscut saw. An excellent question indeed and further evidence of your superior intelligence!

Some crosscuts in timber work benefit from a longer reach. But more importantly, while the longer handle provides less power than the shumoku handle, it provides more control, essential for precise crosscuts. The way it was explained to me is that the large bukkiri gagari rip saw is used up close to the face and “guided by the nose,” while the large crosscut saw is guided from further away by the eye. Give it a try and you’ll see what I mean.

Although I haven’t used these saws professionally for far too long, I had the teeth sharpened and plate tuned a few years ago by a famous blacksmith and saw sharpener named Nakaya Takijiro located in Kawagoe.

In one or two of the photos you may detect the little marks his tapping tapping tapping hammer left on the blade when he trued and corrected it. No, he didn’t straighten it, but he induced internal stresses to relieve some oil canning that had existed from Choujiro’s forge. He also made other subtle stress adjustments with his little hammer that made the saw track straighter and smoother with less friction as it heats up. What a difference it made! He is literally a genius with a sawblade.

The blacksmith’s hand-cut signature on the crosscut saw: “Nakaya Choujiro.” The blade was shaped and tapered in thickness by hand using a “sen” scraper, as evidenced by the visible marks. Close observation reveals that the soft iron tang is not electronically welded to the blade as has become SOP post-WWII, but is forged welded, a technique saw connoisseurs greatly appreciate. Sadly, most of the surface corrosion occurred before your humble servant rescued this excellent saw from durance vile.

I don’t use these saws much anymore, but I enjoy taking them out of their protective wrappings once or twice a year to clean and oil them, catch up on news, and sing a song of sawdust together. They love to sing.

I hope you found this little show-and-tell amusing. I have other unusual saws I will introduce in future.

Until then, I have the honor to remain,

YMHOS

If you have questions or would like to learn more about our tools, please click the see the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

Please share your insights and comments with everyone by using the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, or thuggish Twitter and so won’t sell, share, or profitably “misplace” your information. If I lie may the teeth on my saws all snap off.

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Related Articles

A Few Masterpieces

“Living by faith includes the call to something greater than cowardly self-preservation.”

J.R.R. Tolkein

In this post your humble servant will present a few modern masterpieces of the blacksmith’s art produced recently by a single craftsman. I hope you are as thrilled as I am to know there is at least one craftsman left in the world that can produce chisels of this quality.

The Blacksmith

The craftsman that made these chisels is very unusual in that, unlike the frantically self-promoting, technically mediocre Hollywood blacksmiths such as Tasai, Funatsu, Kiyohisa, and the modern Chiyozuru gang, he is reclusive and shuns attention. Accordingly, I have been requested to not share any personal details about him, so please don’t ask. The fact is I don’t even know his real name just the brand he uses.

I won’t discuss why he is reclusive, but I will go so far as to say that he is self-employed, well-known in his chosen field, and that chisels are not his primary work product but only a sideline. He makes no more than 5 chisels monthly.

His business philosophy and blacksmithing techniques are interesting so I will share some details about them. He has four strict requirements that a Customer must satisfy before he will accept an order. The first two are business-related, and the last two are about the Customer.

  1. The Blacksmith sets the delivery schedule. Period.
  2. The Blacksmith sets the price. Period
  3. The Customer must be a professional worker in wood who needs and will use the tools the Blacksmith will forge daily. His track record must be independently verifiable. Amateurs and/or hobbyists, regardless of their skill levels, need not apply. Collectors are specifically unwelcome.
  4. Besides being expert in the use of chisels, the Customer must have a minimum level of skills, including the ability to make chisel handles and cut a high-quality Japanese plane block using only hand tools. Once again, this must be verified before an order will be accepted.

Your humble servant commissioned a few chisels from the Blacksmith many years ago and went through this same qualification process, although I didn’t realize it at the time.

The quality of his forging and heat-treat technique is unsurpassed producing a crystalline structure in hard steel that will take an extremely sharp edge, will hold that edge without easily dulling, chipping or rolling while cutting a lot of wood, and is easily sharpened.

But it is his metal shaping and finishing skills that are so awe-inspiring. Please notice the straightness and cleanness of the lines and planes, as well as the uniform and smooth curvature at the shoulders, and perfect symmetry. If Gentle Reader is unimpressed, I encourage you to make a full-scale model from cold wood before trying it in hot metal. I promise you will be convinced.

The Blacksmith uses only “free-forging” techniques, and does not employ the rough shaping dies other modern blacksmiths rely on to improve production speed. His forging technique is so sublime that the entire chisel is shaped to nearly final dimension by fire and hammer, not grinders and belt sanders.

He finishes his products using only hand-powered scrapers (sen) and files.

The performance of Blacksmith’s products are equal to or better than those of Kiyotada back in the day, and are more precisely shaped and more beautifully finished than those of Ichihiro (the Yamazaki Brothers) at their very best. They are simply the best chisels that have been made in Japan in the last 70 years.

Let’s take a look at four chisels recently completed for a Beloved Customer in the USA.

34 x 485mm Anaya Chisel

The Anaya chisel is an antique style used for cutting deep mortises and making other joints in large timbers. It is no longer commercially available.

Top view of a Anaya 34x485mm Anaya chisel
Ura view of 34x485mm Anaya chisel
Side view of 34x485mm Anaya chisel

57 x 485mm Anaya Chisel

42 x 490mm Bachi Nomi

The Bachi nomi is the equivalent to the fishtail chisel in English-speaking countries. The word bachi comes from the splayed tool used to play the 3-string Japanese shamisen, a banjo-type musical instrument. Here is a link to a video of two ladies using shamisen and bachi to perform a famous traditional song in Tokyo.

The Bachi nomi excells at getting into tight places to cut joints with acute internal angles such as the dovetail joints that connect beams to purlins.

There are several ways to resolve the angles at the tool’s face, but in this case the Beloved Customer and Blacksmith agreed on the most difficult, rigid and beautiful solution, the shinogi. This design has the advantage of maintaining a shallower side-bevel angle from cutting edge to neck return providing better clearance in tight dovetail joints.

The handwork performed on this chisel’s face is simply amazing, but the hollow-ground ura is even more spectacular to those who know about this things.

54 x 540mm Sotomaru Incannel Gouge

The Sotomaru or incannel gouge is a strong and convenient chisel used for cutting joints in logs and rounded members on architecture. More information can be found at this link.

This is an especially beautiful example as seen the symmetrical confluence of planes and curves at the shoulders.

Conclusion

I hope Gentle Reader found this post informative. You will never find better examples of the Japanese blacksmith’s art outside of one particular museum. It is exciting to consider that there is still one craftsman alive that can routinely perform this level of work.

While your humble servant has praised these chisels and the blacksmith that made them highly, please do not make the mistake of assuming that I am soliciting orders, or even suggesting that commissioning them is possible, because they are simply not available at any price. Please don’t ask.

YMHOS

If you have questions or would like to learn more about our tools, please click the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

Please share your insights and comments with everyone in the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, or thuggish Twitter and so won’t sell, share, or profitably “misplace” your information. May my ootsukinomi roll from my workbench and land cutting-edge down on my toes if I lie.

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The Mystery of the Brittle Blade

There are few blessings without a curse hidden inside, nor curses without a whiff of blessing. Like most things, it’s a matter of how you look at it.

Joe Abercrombie, Isern, “A Little Hatred”

In this article your humble servant will attempt to shed more light on the ancient “Mystery of Steel.”

This story does not begin on a dark Scottish moor, nor on a foggy London night in a drawing room with the door inexplicably locked from the inside concealing bloody mayhem splattered across intricately carved linenfold oak paneling; Rather, it begins in an ordinary woodworking shop. And it goes something like this.

The Brittle Edge

The curtain rises on a humble detached workshop where, unbeknownst to our victim, an erstwhile woodworker we shall call “Woody,” dastardly events are about to unfold (cue the deep, ominous music). It’s really just an old dilapidated garage, but it’s Woody’s kingdom and he is master here, or so his bench cat allows him to imagine. He’s expecting us, so we’ll just go on in.

Make sure the door is firmly closed behind you now; It tends to stick and Woody’s bench dog loves to jet out and root around in the neighbor’s garbage. No mystery about why they call the fuzzy leg-humper “Stinky.” (ツ)

Pine and cedar plane shavings litter the floor of Woody’s shop and their fragrant aroma fills the air erasing the mutt funk. Autumn sunlight filters gently through the single dusty window as sawdust motes dance above a limp bench cat sleeping at the far end of the workbench dreaming of buffalo wings and big-eyed kittens. All appears well in Woody World.

Woody’s sitting at his workbench on his white Smith & Wesson padded stool where he has just unpacked his new chisel, admired it, checked the fit, finish and edge, and appears quite satisfied. He lays out a test mortise hole on a piece of scrap oak, picks up his gennou hammer (the one with the classic Kosaburo head and the sexy Osage Orange handle that turned out so well), and begins to chop a test mortise. But, wait!… Something’s not right!

With trembling hands, Woody examines the chisel’s cutting edge to discover the last thousandth of an inch or so has changed from smooth and sharp to ragged and dull. “Nooooo!” Woody wails as he lifts his arms to the ceiling, arches his back, and slumps to the floor on his knees in a pose reminiscent of Sergent Elias in that poignant moment on a battlefield in Vietnam; “I have been betrayed!” he cries with wavering voice. Yes, Woody’s a talented and enthusiastic drama queen in the Smeagle mold; Maybe even good enough to run for the US Congress.

Another of Woody’s qualifications for high public office is that he dearly loves to pull a cork, so while he walks to the corner Piggly Wiggly to get a 5th of tequila to anesthetize his emotional shock and refill his thespian fuel tanks, let’s take a load off and sit on his workshop sofa over there while I explain the cause of his emotional fragility. Yep, you’re right; It’s a recycled bench seat from an old Dodge Power Wagon he salvaged from a junkyard and converted to a sofa for watching ballgames and taking naps in the shop away from the jaundiced eye of “She Who Must Be Obeyed.” Don’t worry about your pretty pink dress, princess, it’s just honest sawdust.

With tools, tequila, and the mystery of steel involved, this could be a long story, so let’s consider how to solve this particular mystery before Woody gets back and starts up his caterwauling again.

But just so you don’t become discouraged, let me state right now that while all seems dark and hopeless to Woody now, there is a tunnel at the end of the light, and he may actually have reason to rejoice greatly! But we’ll get back to that later in the story.

The Questions

A Japanese blacksmith fluxing and placing a piece of high-carbon steel onto a hot piece of jigane in preparation for forge-welding the lamination of a blade.

Your humble servant always asks the following questions when someone complains of a chipped cutting edge on a chisel or plane. When Woody gets back, and if he manages to remain coherent and vertical long enough, we’ll ask him these same questions. If your blades are causing you grief, you should consider asking yourself these questions too. Jose Cuervo and acting skills are not required.

  1. What sort of quality is your problem chisel/plane? Low? Medium? High? How do you know? This is relevant because a poor-quality chisel/plane will fail just by looking at it too hard;
  2. What type of chisel is it? A striking chisel or a paring chisel? Each type of chisel is used for different tasks and in different ways;
  3. What and how were you cutting when the edge failed? This is important because some woods are best cut in a different manner than others, and some cuts require a special approach if we are to avoid damaging the tool;
  4. What is the bevel angle? If the angle is much less than the ideal for the type of chisel/plane, cut and wood, we may have found the culprit. Finding the perfect angle for your chisel and situation may take some experimentation;
  5. How did the edge fail? Did it crumble? Chip? Roll? Dent? A combo failure (with cheese)? This will tell us a lot about the tool.
  6. Was the wood you were cutting dirty? Did it contain embedded grit? This is an important question because many people carelessly use their valuable chisels, planes and powertools to cut hard minerals instead of scrumptious wood. The lesson? Don’t be a slob: Scrub your wood with a steel brush before cutting it. And saw off the last 3~4 millimeters off both ends of every board, or at least chamfer the ends with a block plane, drawknife or knife to remove the grit always embedded in end grain, before you put it through your jointer, thickness planner or tablesaw, or cut it with handsaws, planes or chisel. If you have not made a habit of doing this, don your scratchy sackcloth tidy whities, smear ashes on your face, then repent and be baptized because you have been abusing your innocent tools, Bubba. Clean your wood and you will notice the difference. Strange that no one I have ever asked this question to has admitted to using dirty, stony wood at first. The reason is usually simply that they didn’t realize it was filthy until I pointed it out to them, just as it was pointed out to me many years ago. What’s that you say? You don’t have a stiff steel wire brush in your toolbox?! Shame on you;
  7. Did you abuse the chisel by trying to lever wood out of the cut, a mortise for instance? This is a common cause of failure. People accustomed to using amateur-grade tools with soft cutting edges frequently discover the edge of their new chisel has chipped after using it like a cheap Chinese screwdriver to lever waste, never imagining the harder and more brittle steel of a quality chisel might be damaged. Such boorish behavior voids the warranty on our chisels, BTW, because a chisel is a cutting tool, not a prybar, can opener, or paint stirrer, much less a screwdriver.

Did your answers to these questions suggest any remedial action to you? The best answer to Question 1 is often to procure a better-performing tool.

But if your tool is professional-grade instead of hardware-store grade, then you may need to learn how to use it and maintain it properly. But that is a story for another day.

Let us shift our attention briefly to another, related mystery, one that has more to do with human nature.

Why Are the Blades of So Many Modern Tools Mediocre Performers?

It wasn’t always that way, but there are sound business reasons why chisel and plane blades are such poor performers nowadays, even in Japan, and like many things, it boils down to money. The numbers of craftsmen that routinely use handtools has decreased, and therefore the demand for professional-grade tools is way down. In Western countries the degradation of tool standards started even earlier.

In this situation, and where customer expectations are as high as an earthworm’s vest pocket, mediocre tools are simply more profitable for manufacturers and retailers. After all, low-quality materials are cheaper and it only takes ordinary machines and minimum-wage factory workers, not expensive trained blacksmiths, to make tool-shaped objects from mediocre-quality materials. Professional woodworkers won’t touch such crap, but amateurs, the inexperienced and those bewildered souls who judge performance based solely on lowest cost buy them by the ton.

More now than ever, “sustainability” is given pious, pompous lip-service, while the reality of modern society is that high-volume sales of colorful but poor-quality tools designed to meet planned obsolescence goals, manufactured in lots of thousands by Chinese farmers, and destined to become early landfill stuffing has become the only viable business model left standing. Gofigga.

More importantly, even if they would do better if given half a chance, inexperienced amateurs seldom have anyone to teach them how to use and maintain their tools, so they never learn proper maintenance principles and cutting techniques. When they damage their woodworking tool blades carelessly, they blame the tool supplier for their own failure. As Mr. T would say: “I pity the fool.”

Faced with this sort of consumer, it is simply easier and more profitable for tool companies to manufacture, and for retailers to sell, chisels and planes with softer, tougher blades suited to amateurs. I think you can see the vicious cycle.

A kakuuchi oiirenomi chisel by Hidari no Ichihiro
An Atsunomi chisel by Hidari no Ichihiro

A Non-technical Technical Explanation

Your humble servant’s earlier comment that Woody may have cause to rejoice about what appears to be metallurgical malfeasance may cause some Gentle Readers to wonder if I am mad as a sack of owls; Perhaps my most excellent aluminum-foil skull cap (the one with purty curly copper wires) malfunctioned permitting those icky inter-dimensional aliens’ mind-control waves to leak through.

Like our absent drama queen, I too was devastated when first faced with a manifestation of the Mystery of the Brittle Blade many years ago, but I can now explain why it may be sign of a blessing instead of a curse. But allow your unworthy and slothful servant to provide some background and explain some time proven solutions before presenting the good news. Steak before ice-cream, you see.

I beg the indulgence of knowledgeable Gentle Readers who feel insulted by the lack of temperature curve drawings and jargon such as “pearlite,” “martensite” and “ austentite,” and ask them to understand that, while this blog is focused primarily on informing our professional Beloved Customers, many Gentle Readers require a less technical explanation. Simple hospitality demands that your humble servant make an effort to provide useful insight to a wide range of Gentle Readers. As a dude wearing a skirt and sandals in a movie once said: “ Are you not entertained?”

A shinogi oiirenomi chisel blade by Hidari no Ichihiro

Quenching the Blade

When a blacksmith quenches a high-carbon steel blade in water in the ancient manner (called “Yakiire” 焼き入れ in Japanese which translates to “burn in” in English), the steel suffers a thermal shock, sometimes severe enough to crack it. This violent cooling also causes a peculiar crystalline structure to form in the metal, one that causes it to become harder and increase in volume, and even to warp to some degree. The casual observer may imagine the water cools the entire blade uniformly, but ‘tain’t so.

Those areas of the blade that cool the quickest form the highest volume of crystals and become hardest. In the case of chisels, planes, and kiridashi knives, the end of the blade has the most exposure to water, cools quickest, and therefore becomes hardest, at least during the first quench.

The blacksmith may carefully repeat the heating and quenching process multiple times, sometimes varying the heat time and temperature to achieve the desired crystalline structure and uniform distribution of small, hard carbides that define “fine-grained steel,” but the quenching process by itself always leaves the blade too hard and too brittle to be useful as-is.

Tempering the Blade

Now that the blade is hardened, indeed too hard, the blacksmith must mellow the steel, reducing its hardness while at the same time increasing its toughness by carefully reheating and cooling the steel to modify the crystallized steel in a process called “tempering,” in English and “yakimodoshi “ 焼戻し ( literally “ burn return” ) in Japanese. In this way, a steel blade hardened to Rc85 degrees during the first quench, indeed brittle enough to break into pieces if dropped onto a concrete floor, can be softened to a useful hardness while becoming at the same time much tougher.

In materials science and metallurgy, toughness is defined as the ability of a material to absorb energy and elastically deform without fracturing. To “elastically deform” means an object changes shape or deforms when pressure is applied, but returns to its original shape when the pressure is removed. For example, if you clamp one end of a piece of mild-steel wire in a vise and apply a little force with your hand at the other end it will bend at first and then spring back to its original shape when you remove pressure. This is an example of “elastic deformation.” But if you apply enough pressure the wire will not spring back (“rebound”) but will remain bent. This permanent bend is called “plastic deformation.” Mild steel wire is truly “tough as nails.”

Glass is the opposite case. While it exhibits more elastic deformation than most people realize it can, it will tolerate no plastic deformation, because when the stresses in glass reach the “yield point,” instead of bending plastically, it breaks.

A brittle blade is hard but not tough, and while it will elastically deform a little bit (often so little it’s unnoticeable), it too easily breaks. Proper tempering therefore, is critical to obtain useful toughness.

But this reduction in hardness and increase in toughness brought about through tempering is not always 100% uniform, and as mentioned above, the extreme cutting edge of the blade of a chisel or plane tends to be hardest and therefore most brittle in the case of hand-forged tools, even after tempering. The cheap, mass-production solution is to simply make the entire blade softer, say Rc55 for example, so brittleness will never be a problem. But such a tool is more a sharpened screwdriver than a cutting tool suited to the needs of professional woodworkers, IMHO.

I’m being too harsh, you say? Not even a little bit. A soft blade dulls quickly, wastes the professional woodworker’s time and money, and is irritating instead of useful. Perfect for turning screws, spreading spackle or stirring paint but not much good for quickly and precisely cutting lots of wood for pay, thank you very much.

Solutions 1 & 2

The Mystery we are investigating on Woody’s behalf is as ancient as steel itself. And of course there are reliable ancient solutions our blacksmiths employ. Let’s consider two of them.

First, create a crystalline structure in the blade through hand-forging that is more resistant to fracturing than ordinary steel regardless of its hardness. The difference hand-forging produces occurs in the crystalline structures in the steel and is not visible to the naked eye. It doesn’t happen by accident.

Second, employ painstaking heat-treatment techniques combined with uncompromising quality control to achieve the right balance of hardness vs. toughness.

To help control the heat-treat process, our blacksmiths apply a special mud-like compound to specific areas of the blade to slow down the thermal shock during the quench and improve the steel’s crystalline structure. Every blacksmith has their own “secret sauce,” so I can’t tell you what it contains, but I’m confident there’s no mayonnaise or Tabasco Sauce involved. This technique is not unique to Japan, BTW, but we know it has been successfully used by Japanese swordsmiths for at least 900+ years. I’m confident there were some old boys in ancient Syria and India that had the knack too.

It ain’t rocket surgery, but factory workers in Guangzhou or Mumbai can’t do it even with unlimited supplies of Tabasco Sauce.

So, we have discussed the reasons, and some solutions, but what to do about a blade that’s already chippy?

Solution 3

Assuming the blade has been forged by an expert blacksmith in accordance with the principles outlined above, as our tools are, the fix to chippiness (oops, did I coin a word?) is to be patient and sharpen the blade three or four times thereby removing the extra-brittle steel exposed at the cutting edge, the area that became harder and less tough than the rest of the blade during the heat-treating process. With few exceptions, the blade will then “calm down” and stop misbehaving.

This is the solution we ask our Beloved Customers to employ when this problem infrequently arises. It requires faith, and patience, but it almost always works.

Solution 4

The last solution, and one I certainly do not recommend to anyone except as a last resort, is to heat the cutting edge under a candle flame. Not an acetylene torch; Not a propane torch; Not even a butane cigarette lighter; A candle flame only. You want the extreme cutting edge to become just a smidge hotter than you can comfortably touch with your bare finger. Don’t heat the entire blade, just the cutting edge.

BIG FRIKIN DISCLAIMER 1: This method won’t fix a poor-quality blade or one that was initially ruined during forging or heat-treat.

BIG FRIKIN DISCLAIMER 2: If you do this wrong you can easily ruin the blade!

Rejoice Greatly!

But what parasitic-worm-induced brain fever made your silly deranged servant suggest that Woody should rejoice when the cutting edge of his new chisel crumbles? I assure you, my reasoning is sound, I have Woody’s best interests at heart, and I will explain all to him when he sobers up. Probably tomorrow afternoon, at this rate. (ツ)

But I’ll explain it now to you, Beloved Customer, if you will be good enough to get me a root beer to wet my whistle from Woody’s cooler over there. No, that’s not a Class M-3 Model B-9 General Utility Non-Theorizing Environmental Control Robot, it’s one of those mini-fridges sitting on two skateboards with a shop-vac wrapped in Christmas lights perched on top that Woody puts out on his front porch for Halloween to thrill the kids and to keep a sufficient stash of cold adult beverages, and root beer too, of course, close at hand. He’s very practical that way. Oh, BTW, please don’t tell SWMBO about the adult beverages, or you’ll ruin a great Halloween tradition and preclude many erudite discussions in the future: Vino Veritas

Ahh, that’s better. Nothing like an ice-cold root beer.

Now where was I? Oh yes, the reason for my optimism: A high-quality blade that crumbles like Woody’s did when brand new, and mellows after a few sharpenings, is highly likely to be an exceptionally fine tool!

On the other hand, a blade that is too soft when new will never crumble or chip, but it will always quickly dull and never improve. A veritable gasket scraper. (个_个)

There are exceptions, of course: some hand-forged blades are defective and crumbly from beginning to end, usually a result of overheating the steel during the forging process (called “burning” the steel), a rookie mistake. You should return such a defective blade to the retailer you purchased it from. If, however, to save a few bucks, you rolled the dice and bought a tool without a warranty, or purchased it from an online auction, to obtain satisfaction you will need to enlist the services of Murphy’s two bubbly buddies at the law firm of Doodly & Squat. Good luck with that!

Somehow I doubt Woody will thank me for solving this piece of the Mystery of Steel for him, but I am confident he will love the flavor of that chisel for the rest of his life.

YMHOS

PS: If you found this interesting, you may find other posts regarding the Mystery of Steel found in our “Sharpening Series” interesting too. The one at this link in particular is relevant to this discussion.

A kakuuchi oiirenomi chisel by Hidari no Ichihiro. The blade has been polished removing the black oxide formed in the forge. Beautiful work like this is no longer available.

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The Story of a Few Steels

Professional-grade Tools

The Ogre and the Blacksmith

The Blacksmith and his daughter

The following is an old tale from Japan’s Toyama Prefecture. It’s not exactly a Christmas story, but includes all the classical elements a story shared on a cold winter’s eve must have: A beautiful maiden, a cranky blacksmith, an elemental creature, magic, weapons of death and destruction, an impossible challenge, and of course…, chickens. I hope you enjoy it.

Long long ago and far far away in a country in Japan called Etchu (modern day Toyama Prefecture) there was a large blacksmith’s shop.

The owner of the smithy, called “Master Blacksmith,” was well-to-do with many craftsmen working for him. He lived in a big house called a chouja.

The Hagiwara Chouja

Master Blacksmith had a single daughter of marriageable age, a rare beauty with almond eyes and long black hair shiny as a raven’s wing.

One day he announced to all the craftsmen in the area that he would give the hand of this daughter to the first suitor to forge 1,000 spearheads in a single night.

A classical Japanese “straight spear” (直槍) spearhead, distinctly different from most Western spears.
A “Cross” spearhead (十文字槍) used to thrust, parry blows and pull horsemen to the ground, a difficult piece of work for the blacksmith to forge, and infamous for turning the fingers of professional sharpeners sticky red (seriously). 

But no matter how skilled, every weapons blacksmith knows that it’s impossible to forge 1,000 spearheads in a single night, so his challenge went unanswered.

Master Blacksmith decided he needed to expand his offer and so put up a notice board describing his challenge alongside the main road for passersby to see, and waited for skilled craftsmen to appear.

おぉセクシーすぎるぞ!海洋堂も参加、鬼北町に誕生した巨大な女鬼のモニュメントのインパクトったらない

Lo and behold an ogre that lived on a nearby mountain meandered by late one night and saw the notice. It did a little jig the way happy ogres do and gleefully exclaimed “Ha ha hee heee! A thousand spearheads is easy for meee!

The next morning, using the elemental magic that many ogres have, it changed his appearance to that of a young man and went down the mountain to Master Blacksmith’s house.

The Master looked doubtfully at the ogre in the shape of a young man and disdainfully said “What makes a young fella like you think he can make a thousand spearheads in one night?”

The ogre responded, “I can do it. I will surely make them before the cock crows in the morning.”

Thinking he had nothing to loose, the Master responded: “Then make them if you can.”

As the sun went down, the ogre in the shape of a young man went into the smithy, closed the doors, and began working.

Master Blacksmith heard sounds like the wind blowing from inside his smithy, but nary the sound of  a hammer striking metal or the ringing of an anvil. Perplexed, he said to himself “What can he be doing in there?”

Slipping quietly around to the back of his smithy and peeking through a crack in the siding boards, Master Blacksmith was shocked as he had never been shocked before because he saw fire spewing from the young man’s mouth as he bent and folded and shaped yellow-hot steel in his bare hands like it was warm taffy!

Before his eyes a smoking stack of completed spearheads quickly grew. It became obvious to Master Blacksmith that all 1,000 spearheads would be finished well before dawn.

Fearful for his tender daughter, Master Blacksmith realized he had to do something to stop the strange young man from successfully completing the challenge, so he thought and thought and thought until his thinker overheated.

“The only way out of this mess I have made is for the cock to crow before all 1,000 spearheads are completed,” he eventually reasoned. Following this logic to it’s natural conclusion, he took a jar of hot water into the chicken coop where the chickens were all fast asleep dreaming of stretchy worms and crunchy beetles.

Desperate to make even a single chicken crow, he poured the hot water on the roost where the chickens slept soundly. The surprised chickens all woke at once in a panic with the hens squacking, cackling, and screaming while the roosters all crowed out “Cock-a-doodly dooooo!”

Hearing this racket from the chicken coop the ogre in the form of a young man became frightened, wailing out “I have been discovered!”

Instantly, the magic that had changed its appearance popped like a soap bubble revealing the ogre’s supernatural red skin, yellow horns, and shiny white fangs again. The ogre ran out of the smithy like ten stampeding bulls raising a cloud of smoke all the way back to the mountain where it came from never to be seen again. 

With this, the blacksmith rubbed his chest and exclaimed in relief “I see, he was an ogre after all!” 

“And just what is this?” he said as he walked fearfully over the shattered remains of the front door to his smithy and peered inside in amazement at the stack of smoking-hot, sparkling spearheads left behind by the ogre. Indeed, it turned out the red ogre had left behind exactly 999 completed spearheads, each wonderfully made.

From that day forward the blacksmith’s shop was famous for the quality of its spearheads, which are still known as “ogre-spears.”

And the blacksmith became wealthier than ever.

The End

Even ogres need love

YMHOS

If you have questions or would like to learn more about our tools, please use the “Contact Us” form located immediately below. Please share your insights and comments with all Gentle Readers by using the form located further below labeled “Leave a Reply.” We aren’t evil Google, incompetent facebook, criminal Twitter, or the Chinese girlfriend/fundraiser of a Congressman, and so won’t sell, share, or profitably “misplace” your information.

The Carpenter and the Angel

For a change of pace, I would like to share this charming folktale from Kagoshima Prefecture, Japan, of a sort traditionally told to small children.

We originally posted this little story about a year ago, but subsequently some pesky pixies seem to have pulled it down, so we are re-publishing it today for Japan’s Labor Thanksgiving Day holiday and because Tengo was such a great workman (or at least labor producer).

I have included photo extracts from the Kasuga Gongen Genki E (春日権現験記絵) scrolls painted in 1309 on silk using silver and gold paints, showing carpenters working on the Kasuga Shrine jobsite in Nara back in the day.

My children and I enjoyed this story. Perhaps you and yours will too.

The Tale of Tengo and Tenjin

Once upon a time there was a very good carpenter. But he was sad because he lived alone, so he asked the prettiest girl in the village to be his bride.

She did not want to marry, but to put him off without hurting his feelings, she decided to charge him with an impossible task. 

“If you will build me a big house with 60 tatami mats in a single day, then I will marry you.” (60 tatami mats = approx 99 square meters = 1065 sqft based on the standard modern tatami mat) 

The carpenter was shocked by this demand, but because he wanted her for his bride, he boldly accepted the challenge saying: “I will build you this house in one day.” 

His voice rang with confidence as he said this, but he despaired in his heart knowing he could not build such a large and beautiful house in one day. He thought to himself  “ What shall I do, what shall I do?”

But never fear, because as you have probably guessed, our carpenter was no ordinary fellow to give up easily. Before long he came up with a plan.

He made 2,000 dolls out of straw and breathed on each while casting a magical spell transforming them all into human carpenters. 

The carpenter and his 2,000 man crew then went to work.

Images from the “Kasuga Gongen Genki E,” completed in 1309. At the top of this image, the Master Carpenter and his helper use a water trough as a water level for layout. He uses a vertical string of a fixed length with a plumb bob attached to check the high stringline’s height above the water’s surface to adjust the line to be approximately level. At the center-right, A crew of 3 workmen excavate a hole and compact the soil at the intersection of two low stringlines installed by the Master Carpenter in preparation for placing a natural foundation stone, probably intended to support a main post. Notice the shovel: a wooden blade and handle fitted with a joined “T” handle and with a steel or iron cutting edge affixed. Bleeding-edge technology at the time.
The carpenter and his young helper in the drawing’s upper half use a sumitsubo (inkpot) to snap a straight line on a timber in preparation for splitting it into boards. At the lower right, the master carpenter uses his sumitsubo inkline as a plumbline to orient his steel square to vertical against the log’s end. At the same time, he directs his mellow-looking partner at the opposite end to make a matching vertical line using a steel square with a bamboo pen wet with ink from the reservoir of his classic split-tail sumitsubo. Notice how he used an adze to keep the log from rolling away as they fiddle with their squares and inkpots.
The carpenters in the upper right use chisels to split timbers, while the other workers use adzes to dimension and clean split boards. Unusual for ancient Japan, this appears to be an ethnically-diverse crew with one workman apparently being of African persuasion (ツ). Notice the classic carpenter’s toolbox at the far left with a leaf-blade saw secured to the lid and a wooden mallet laying next to it on the ground
At the top of this image you can see two carpenters, one shaping the end of a round column with a spear-plane (yariganna) and another sawing what appears to be a kumimono bracket with a leaf-shaped saw as he jabbers at his buddy a hundred miles an hour. In the center, more carpenters use spear planes to smooth adzed boards and a round column. Notice the wood shavings curling from the curved blades, some being pushed and others pulled. Spear planes were used in Japan long before blade-in-block planes became common. The guy working on the board’s right hand end appears to have his thumb stuck in his eye. I hate it when that happens!
Carpenters erecting a building’s structure in a later century. No ginpoles, hardhats, shoes, or tie-offs are in sight. Probably no hardhats either. And the scaffolding is a death trap! Tisk, tisk! What would OSHA say?
A diagonal view of the coved & coffered ceiling at the family room.
A corner view of the family room coved & coffered ceiling. Notice the coped joints. This work is typically performed by joiners, not carpenters.
Related image
The living room has an even more elegant coved & coffered ceiling with “kumimono” brackets.
The living room’s coved & coffered ceiling in hinoki wood with a carved “rainbow beam” in the foreground. Nice work!

With the assistance of his 2,000 helpers, the the carpenter completed building his bride-to-be’s house before the sun went down that day,

Overjoyed, the carpenter flew to his bride-to-be’s house to tell her of his success. “I have finished the house you asked for. Please marry me now!”

“Truly?” she asked. Upon inspecting the work she found a big, beautiful house with 60 tatami mats, just as she had stipulated. “I will marry you.” she said.

And thus the prettiest girl in the village became the carpenter’s bride.

The carpenter and his bride then moved into their happy new home.

Afterwards, the 2,000 magically-created workers scattered throughout Japan to build houses, temples and bridges and teach many other carpenters how to build beautiful things for many years.

After several happy years had passed, the bride said to her husband “I have been silent up to now, but the time has come to tell you the whole truth. I am not really a human being, but an angel named Tenjin. I came down to earth from the kingdom of heaven. But the time has now come for me to return to heaven.”

The carpenter replied: “Ah, well, now that you mention it, I’m not actually a regular being either, but a carpenter god named Tengo. Let’s both return to heaven together.”

So Tengo and Tenjin rose high into heaven where they still live happily ever after.

The End

YMHOS

If you have questions or would like to learn more about our tools, please use the “Contact Us” form located immediately below. Please share your insights and comments with all Gentle Readers by using the form located further below labeled “Leave a Reply.” We aren’t evil Google, incompetent facebook, or twitchy Twitter and so won’t sell, share, or profitably “misplace” your information.

The Tale of the Blacksmith’s Granny

The following is an old country folktale of the sort a grandfather would tell his grandchildren before bedtime. So imagine you are little boy or girl sitting around an irori fire with your family on a full-moon autumn night, with the wind rustling the dried leaves on the trees just outside the closed wooden amado doors, as your white-bearded grandfather tells you this tale. Don’t be frightened!

This image has an empty alt attribute; its file name is a0220433_938222.jpg

Long ago and far away a traveling merchant was crossing over a mountain in the country of Oki in Japan (Sanin area) at  sunset. As he reached the highest point he came upon a large lone pine tree with a crotch at about twice a man’s height. Using a bit of rope he always carried, the chubby merchant managed to pull himself up into the crotch and fell soundly asleep as the darkness deepened around him.

Hearing a strange sound, the merchant woke suddenly and was shocked to see his tree surrounded by dozens of large, long-toothed goblin cats glaring up at him in the darkness and yowling. He panicked fearing the monsters would jump into the tree and attack, and him without any way to escape. But all he could do was sit in the tree and pray the goblin cats would just go away.

At some point the beleaguered merchant began to realize the goblin cats were not just yowling but were actually speaking words he could just make out.

“My fellow goblin cats” said the boss cat. “That plump human in yon tree is the perfect main course for our banquet tonight, but obviously we can’t wait here all night for it to fall out.” The largest cat proposed a solution. “Noble goblin cats, I tell you what; I’ll climb the tree and push the fat lump out. When he hits the ground you jump on him, and our feast will  be secured.” Without waiting for a response from his demonic feline friends the goblin cat placed a stick against the tree’s trunk, extended his sharp claws, and using the stick for his first step, slowly crept up the tree trunk towards the intended victuals.

Hearing these strange words and seeing the boss goblin cat’s preparations, the merchant realized he was facing a sticky end best avoided, so he quietly unsheathed his long 9sun 5bu dagger (288mm, 11.3 inches) and readied it for the cat’s attack. (If you like blades, here are some links to YouTube videos of beautiful formally recognized historical examples: (Yoshimitsu tanto (designated National Treasure); A tanto by Sukesada of the Osafune School of Bizen in the “yoroidoushi” style intended to penetrate armor. A tanto designated as a “Tangible Cultural Property” with the name “Uebataima“.)

The plump merchant couldn’t see anything in the poor light, but he heard the frightening sound of the goblin cat’s claws cutting into the treebark as it climbed “Zaku.., zaku…, zaku..” 

He thought to himself “Here it comes!” “Just a little more now!!”

Suddenly the merchant saw the cat’s face just as it leaped at him with hooked claws extended and salivating fangs bared, but the merchant’s dagger pierced deeply into the big goblin cat’s abdomen releasing a fountain of blood, killing it instantly. The cat’s body collapsed in the same tree crotch with the merchant.

The goblin cats surrounding the base of the tree yowled and screeched like the demons from hell they were as they circled the tree’s base, shredding the bark with their wickedly sharp claws, then yowled and screeched some more. At last one of the evil creatures calmed down enough to say “It seems tonight’s dinner is more formidable than we first thought.” Hearing this, the merchant pushed the dead goblin cat’s limp and sticky body out of the tree so it landed with a wet thump right in front of furious goblin cats circling below.

Looking at their expired leader’s body, the goblin cats all jumped twisting into the air, cutting with their claws, spitting, frothing, screeching and yowling even harder. Then one said angrily “Now dinner’s gone and done it! This means war!” Spitting, hissing, and screaming things I won’t repeat to you children the goblin cats all scrambled up the tree towards the merchant getting in each other’s way and making a real hash of the job. In the confusion the merchant, who wasn’t really all that good with weapons, used his dagger to hack and stab every goblin cat that came within his reach killing and injuring more of the monsters.

The surviving goblin cats stopped their reckless attack and huddled panting and bloodied at the tree’s base arguing how to deal with this difficult menu item. “What shall we doooooo! What shall we doooooo!!“ they yowled up at the sky in frustration.

As they gradually calmed down one cool cat said “We must avenge these foul murders even if we all die in the attempt.” Another cat added “I’m not afraid to die but I worry about what will become of our mates and kittens if we are killed.”

The cool cat thought for a minute and finally said “Ok, here’s what we’ll do. Let’s go ask the blacksmith’s granny for help.” And with that all the goblin cats sped off into the dark like greased lightning.

Seeing his chance to escape, the merchant sheathed his dagger, gathered up his pack, and started to climb down from the tree. But before he could lower himself all the way down from his perch in the tree he heard the rhythmically chanting voices. In the dim light of the rising moon the merchant could just make out a palanquin born by six goblin cats chanting in cadence and surrounded by many others approach and stop beneath his tree. 

Cats carrying a palanquin. Is the blacksmith’s Granny inside?
The interior view of a luxurious lady’s palanquin. A noble lady would have been carried in this conveyance by her female bearers

“This is the place, Granny.” “Please knock that fat human out of this tree so we can eat him at our banquet!” beseeched the goblin cats. 

The palanquin door slowly slid open revealing not a human grandmother but a huge white goblin cat of great dignity wearing a sleeveless kimono with a snow-white shawl over its shoulders. The monster rolled its large eyes in disgust at the smaller goblin cats and said “What is wrong with you useless ninnies?! Can’t you even take care of a pitiful human like that? You bunch are hopeless as yakuza.” 

She paused her berating of her fellow goblin cats, and gazing up into the tree said “Well, I suppose I must knock this human out of the tree myself. Such a bother! You useless idiots stay out of my way now.”

With one voice the smaller goblin cats all yowled “Thank you Grandmother!”

Grandma cat removed her white shawl and handed it to the closest younger goblin cat, then began carefully testing her claws on the tree trunk. When her claws were ready, and without a second look up at the trapped merchant, she slowly began to climb the tree.

Let me pause here, children, to catch my breath and wet my whistle….. Ahh, thank you Hanako, an excellent libation indeed! Your mother’s sake brewing skills improve every year. And you helped, did you? An excellent child. Well done. Just one more sip.

Ah yes, and where was I? That’s right. The huge white goblin cat, who did not look anything like a granny at all, was slowly climbing a tree high in the moonlit mountains, one sharp claw at a time, to kill a plump, tasty human who had repelled and killed several precious members of her goblin cat yakuza gang.

So far the frightened merchant had bravely driven off every attack, but this time his legs were shaking with dread at the memory of the many goblin cats and the boss goblin cat that had attacked him already, but to make things worse, now a huge white monster goblin cat had arrived in a deluxe palanquin no less, and was climbing his tree! What terrible creatures they were! Can you imagine it little children?

Once again he heard the zaku.. zaku… zaku sound of claws cutting into the tree coming closer, but this time the pace seemed slower than before, perhaps because the newly arrived goblin cat was older and bigger. The poor merchant’s whole body shook like a leaf with fear.

It’s getting closer…. It’s almost here!! 

But after another minute passed the big goblin cat still hadn’t reached his roost, so the merchant began to hope he might be able to to fend off the monster with his blade.

He gripped his knife tighter in his sweaty hands… and raised it over his head… just like this!

Suddenly the big goblin cat’s huge eyes appeared right in front of the treed human’s face. Gyaaaaaaa! he screamed in fear.

The monster struck out with its wicked, curved claws cutting the shocked merchant’s face deeply. But the merchant recovered his senses, and despite his injury, cut about wildly with his knife.

The big white goblin cat jumped up onto a limb of the tree and deftly swatted away the merchant’s frantic blows with her huge paws.

In between blows the man and the goblin cat spat curses and gasped for breath covering each other’s face with stringy spittle.

Image

Although it seemed like the battle continued for hours, in less than a minute the merchant had been driven out to the end of the tree limb with no room to retreat. Suddenly, one of the goblin cats down below called out in despair, “Oh no, the sun is rising!”

Hearing this, the big white goblin cat stopped her attack, jumped down from the tree, stepped briskly into the palanquin, slid the door closed, and raced down the mountain road followed by all the other goblin cats scrambling like cockroaches in the sunlight.

As the sun began to rise in the East, the panting merchant collapsed back into his tree crotch. He thought about running far away from the terrible place until he recalled how afraid the goblin cats had seemed of the morning sun. And he thought of getting revenge for his injuries too, but confident there were enough hours of daylight left to make a decision, he collapsed back into his tree crotch and fell into an exhausted sleep. As he slept, he remembered the goblin cats that had first surrounded his tree saying something about the blacksmith’s grandmother.

When the sun was high and bright, the merchant climbed down from his tree, sore in every joint and with deep and painful cuts on his face, and followed the path down the mountain the goblin cats had taken. After he had walked a while he began to hear the “tink tonk tink tonk” sound of a hammer striking metal. Soon he came upon a small blacksmith’s shop with a house nearby. Inside the smithy was sweaty man hammering away at a hoe blade.

“May I ask you a question, good blacksmith?” said the merchant. The blacksmith paused his hammering, looked over the cut and bloody merchant and responded “Yup, what do you want?”

The merchant said “I heard there was a grandmother living around here….”  The blacksmith pointed his hammer towards the house and said “Well, maybe. My granny is been sick and hasn’t left the house over there in a long time.” He raised his chin, squinted his eys at the disheveled merchant, just like this, and asked sharply, “What’s your business?” The merchant calmly answered “I have something to deliver to her.” The blacksmith then asked “Who is it from?” The merchant said “they didn’t give their name, just handed me this package and left.” The package the merchant was holding contained a whole yellowtail tuna fish he had bought at a fishmonger’s shop on the way. It wasn’t a very fresh fish though, and stank badly.

The blacksmith gave the merchant a distrusting look, when from inside the house they heard a hoarse voice croaking out “Saburo!” The blacksmith’s name was apparently Saburo because he called back “Yes, grandmother?” The voice answered “What’s going on?” Saburo answered “Somebody brought you a big fish, grandmother.” “Well, what are you waiting for, bring it here.”

With that, Saburo accepted the stinky fish and took it inside the house. When he returned, the merchant whispered to him explaining the events of the night before and pointing at the deep cuts on his face and arms as evidence. But the blacksmith would not believe the strange story and responded “That’s ridiculous!” “But I tell you, it’s true” said the merchant. “If you doubt me, just take a look for yourself.”

The two men then walked around to the back of the house as quietly as a pair of tiny mice wearing fuzzy bunny slippers, slid open the shoji doors into grandma’s room just a crack, and peered inside where they saw an old woman wearing a white kimono sitting up on her futon. The old woman reached out to the package containing the fish, brought her nose close, and smelled it  “sniff, sniff.” As the two men watched, she greedily snatched the big raw smelly fish from inside the paper packaging and began to greedily bite off large chunks and swallow them.

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With this, the merchant slammed open the shoji door, and jumped into the room. Saburo was too shocked to do anything but let out a roar of indignation. Surprised by the sudden noise, grandma turned back into her true form of a huge, white goblin cat, but before she could attack or flee, the merchant drew his sword and cut down the monster which leaked rivers of bright blue blood and died right there, thank you very much.

Saburo was so shocked by seeing his grandmother change into a monster and then die in a puddle of blue blood he could do nothing but stand there with his mouth hanging open as flies buzzed in and out. 

Finally, the merchant asked “How long has she been alone in this room?” Saburo closed his mouth, opened it again, and said “About three years now.” “Three years, huh? Well your real grandmother is nothing more than bones by now, I wager.”

At the merchant’s urging, the blacksmith and his neighbors searched the house, and towards evening they found a pile of white bones wearing the Blackmith’s grandmother’s kimono under the floor, meaning the big white goblin cat had killed grandma and had been passing itself of as her for 3 whole years.

A sad but all too common story. Time for bed now my little ones.

(A folk tale from Oki Province)

YMHOS

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Cherry Blossoms In Asakusa

“And so the spring buds burst, and so I gaze,
And so the blossoms fall, and so my days …” 

Onitsura

As I walked near my home today I was pleasantly surprised to see plum trees and even a few cherry trees working on their beautiful spring dresses. It reminded me of a day in April when my wife Kazuko and I went to Kappabashi street in Tokyo to buy a seiro, a dumpling steamer made of fragrant bent Akita Cedar wood and bamboo.

I don’t share her fascination for computerized sewing machines, smoothie blenders, and fuzzy bunny slippers, but she is an excellent cook and I would be a fool to deny her every possible assistance in obtaining any food-prep tool she desires.

Kappabashi Market

The entrance to Kappabashi Street, a center for kitchenware and restaurant supplies in Tokyo. If you enjoy cooking and the tools used in that contact sport, you must visit this huge shopping area.
The primary goal for the day: A cedar and bamboo seiro for steaming yummy dumplings. Mmm…. Dumplings.
A dish store in Kappabashi named Komatsuya. The wide angle lens makes it look bigger than it is, but the sheer volume and variety of dishes is not exaggerated.
A knife store in Kappabashi with a 100 year history. When professional chefs in Eastern Japan buy the tools of their profession, this is where they go. There are 8-10 such cutlery stores like this, all selling the world’s best food prep knives.
A bride going for a ride in a human-powered rikisha at Kappabashi.

Kaminari Mon (Lightning Gate)

From Kappabashi we walked to nearby Sensoji Temple, famous for the Kaminari Mon aka “The Lightning Gate” in Asakusa. Crowded with tourists, but good to see every few years.

The huge paper lantern hanging inside the Kaminari Gate at Sensoji Temple in Asakusa. H3.9m x D3.3m x 700kg (1,543lbs). A dragon in clouds is carved into the base.

After purchasing the seiro and other essential items at Kappabashi and visiting Sensouji Temple and Kaminarimon, we went to a little restaurant and enjoyed a nice lunch. After lunch we traveled a little further afield to view the last hours of the year’s cherry blossoms.

Cherry Blossoms

Cherry blossoms have an important place in the hearts of the Japanese people. The seasons change suddenly here and cherry blossoms seem to explode into bloom. For a few days the trees are bright and fluffy and glorious, but as quickly as they appear the individual petals fall to the earth leaving green leaves behind. The fallen flower petals decorate parks, sidewalks and ponds and flow down the rivers in spinning, colorful rafts.

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The Japanese people love to walk underneath blossoming cherry trees, and where possible, spread a blanket under the flowers to enjoy lunch and few adult beverages with family and friends.

桜吹雪

Since ancient times, as evidenced in literature, poetry (see the famous example above), and artwork, the budding, bloom and fall of cherry blossoms have been seen as a metaphor of all living things, including humans. Cherry blossoms represent a quiet, elegant, pure life with an inevitable, unselfish, beautiful ending. The cherry tree shares its bright raiment with everyone; The blossoms dance in the wind that scatters them. No complaints, no regrets, just the cycle of life.

Modest pink cherry blossoms close to the end
夜桜

One of my favorite memories is of walking home from the train station late one night after a long day at work. It was a cold night and the wind was blowing. Fallen cherry blossom petals formed a soft, beautiful snowstorm that whirled around me in an unexpected and sudden blessing of nature.

Setsunai 切ない

Lest any druids or tree-huggers among my Gentle Readers be offended, I will not say that trees do not have emotions, but I think we can agree their language skills are limited. Humans however definitely have emotions and lots of words, so allow me to delve a little deeper into the Japanese language and the emotions cherry blossoms evoke in the hearts of many Japanese people (at least the mature ones). If there is even a little bit of an artist or poet hiding among the dusty barrels in your soul’s basement you should find it interesting.

There is a strange word in the Japanese language pronounced “Setsunai” and written 切ない The direct translation of the characters means “can’t cut.” Strange, right?

The dictionaries translate the word as “painful” (both physical and emotional); sad; or even “heartrending sorrow.” But when used in the context of something as beautiful and inevitable as the budding, flowering, falling, scattering and often muddy end of cherry blossoms, it is used to express the emotions of the quite, sad, unavoidable end of a beautiful thing that once gave joy, a natural event that repeats every year. Not hopelessness or despair, in this case, but sadness after beauty.

A human life is (hopefully) much like this cycle. A baby is born and becomes a happy, energetic child. It grows into an adult, is productive and loving, and imparts beauty into the world. The adult grows old; its beauty and energies change. And the day comes when each human’s physical existence fails and their spirit is carried away, perhaps dancing on the wind like the petals of a cherry blossom. Beautiful on the one hand, sad on the other, but definitely setsunai.

Knowing cherry blossoms will appear next year and the cycle of life will continue tempers the sadness at the loss of such great, unselfish beauty, and gives one hope for the future, at least for a while.

I invite you to read Onitsura’s poem at the top of this blog again. Simple but setsunai indeed.

A craftsman, upon realizing a chisel, plane or saw blade won’t cut may jokingly call it “setsunai,” but not in the poetic sense.

The End of the Day

We enjoyed a beautiful day at Kappabashi and Asakusa, complete with a lunch of tempura soba for me and some sort of raw fish for my patient wife. Life is short and sometimes hard, but it has its beautiful moments. I pray you have many such moments, and that your blossoming will be joyous and your dance on the wind graceful.

Fallen cherry blossoms floating quietly on the Shakujii Park pond. A beautiful ending to a short life. Who could ask for more?

YMHOS

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