Cherry Blossoms in Tokyo

Like to the fleeting world of ours,
Methinks, are the frail cherry-flowers,
For they that bloomed yesterday
Are seen to-day to fade away.

Anonymous

It’s cherry blossom season in Japan.

Your humble servant works hard to keep this website focused on tools, as promised, and strives to not pad it with vain and pointless pictures of pets, projects, or product promotions. But every 4 years or so I like to add a post about cherry blossoms, that beautiful flower so important to the people of this island nation.

These photos are mostly of cherry trees and their blossoms in Tokyo proper, a metropolitan area of a little more than 14 million residents containing approximately 13,400 km2 (5,190 sq mi). But despite the difficulty and cost of maintaining them, Tokyo’s residents love their cherry trees adorned in white and pink dresses, and look forward to visiting and admiring them for a few days every year. This is an old and worthy tradition indeed.

I don’t pretend to know much about flowers, but I love trees. So I am posting this in tribute to the adornment of the cherry tree, for like all things that live, their petals will be glorious for only a few days, then fail. Can any of us hope for finer raiment or a more glorious future?

YMHOS

An old cherry tree in a nearby park. Its trunk and limbs are dark and twisted, but its flowers are lovely as ever.
The same old cherry tree dancing into the sky. Fallen petals are scattered by the wind to decorate the ground for a brief time.
A family has setup a picnic under the cherry tree. I think Treebeard would praise this tree
A row of cherry trees with people enjoying the flowers and a picnic lunch
This old cherry tree is nearing the end of its flowers, but it has turned the asphalt below into a pink carpet.
Even the house across the street, wet with rain, is adorned with petals.
Mrs. YMHOS in her cherry blossom pink best.

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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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Relevant Articles

Japanese Exchangeable Blade Handsaws Part 2 – Pros, Cons & User Improvements

If you want to know what a man’s like, take a good look at how he treats his inferiors, not his equals.

J.K. Rowling, Harry Potter and the Goblet of Fire

Introduction

This is the second in a two part series about Japanese exchangeable-blades handsaws (“kaeba saws”).

In Part 1 we examined the history of how these saws came to be, how they are manufactured, and the market forces that made them so popular in Japan and even overseas. In this conclusion we will consider their advantages and disadvantages compared to traditional fixed-blade saws, and explain a few simple techniques Gentle Reader can employ to improve the performance of one variety.

I think all who have used them will agree that exchangeable-blade handsaws (“kaeba saws”) are effective and convenient products. However, Gentle Reader may be pondering, no doubt with exquisite grace and dignity, the question: “Do kaeba handsaws exhibit performance superior to well-made traditional handsaws?” The simple answer is unequivocal: sometimes yes, sometimes no. The Okey Dokey list below summarizes the reasons supporting your humble servant’s decisive answer.

But to avoid too much confusion, let’s briefly review the materials and techniques used in making the kaeba handsaw before attempting to navigate Okey & Dokey.

Review of Materials and Production

You will recall from Part 1 that kaeba saw blades are manufactured in automated CNC production lines using pre-hardened, pre-sanded, sheet steel of uniform thickness purchased from rolling mills. The sawmaker’s machinery cuts out the blade blanks, deburrs them, punches the teeth, shapes and polishes them with automated precision grinders, adds set to the teeth, and sometimes tensions the blades between rollers. The teeth of some blades are also instantaneously induction heat-treated (what some manufacturers call “impulse hardened) producing teeth harder than a sawfile.

Unlike the blades of traditional, high-quality saws, however, kaeba saw blades are not differentially hardened, taper-ground, trued or hammer-tensioned, nor are their teeth professionally sharpened, tuned or quality inspected. And of course, the backs of backsaws like dozuki are not carefully fitted. These are big, decisive differences not apparent to the untrained eye.

So with these physical differences in mind, let us next consider the pros and cons.

The Okey Dokey List

Some Advantages of Kaeba Handsaws Compared to Traditional Handsaws

  1. Lower Initial Cost: The initial cost of kaeba saws is less than traditional hand-forged saws. This is to be expected as they are mass-produced on automated machinery involving zero handwork by craftsmen.
  2. Greater Convenience: Dull or damaged blades can be quickly replaced with new, sharp blades improving convenience and obviating the need to carry entire bulky spare saws, and to have their teeth resharpened.
  3. Greater Durability: Kaeba sawblades with induction-hardened teeth (aka impulse-hardened teeth) are more durable and remain sharper longer than traditional fixed-blade handsaws, especially when cutting EWP (engineered wood products) such as plywood, MDF, OSB, LVL, glulams, etc. which contain hard adhesives and abrasive sandpaper grit. This is not the case for all kaeba sawblades, of course. From the craftsman’s viewpoint, this is perhaps their most significant performance advantage, and is nothing to sneeze at.
  4. Disposable: Like cat litter, plastic beverage bottles, and modern marriage, kaeba saws are a “use and toss” product that need not be repaired, only replaced. Fortunately, unlike marriage and cat depositions, lawyers don’t get involved much.

Disadvantages of Kaeba Handsaws Compared to Traditional Handsaws

  1. Less Economical Long-term: While cheaper when new, and although some kaeba saw blades can be resharpened (except those with induction-hardened teeth), the cost of a new replacement blade is typically more expensive than the direct cost of a professional sharpening job, another profit motive for planned obsolescence
  2. Limited Blade & Tooth Options: While popular blade and tooth shapes/quantities are readily available, the specialist blade shapes/teeth required for woodworking trades and tasks other than carpentry (e.g. luthier, fine interior joinery, kumiko zaiku, large rip and crosscut work, smooth cutting of hard woods, etc.) are simply not available as kaeba saws often leaving craftsmen who rely solely on kaeba saws bereft of adequate tools. Case in point: most kaeba saw blades are designed to cut the varieties of softwood commonly used in housing construction quickly and efficiently but are not well suited to cutting most hardwoods smoothly or precisely. On the other hand, some craftsmen and certainly professional saw sharpeners can readily modify the teeth of a traditional saw to satisfy specific job requirements. Younger craftsmen that grew up using only kaeba saws do not even realize this sad state of affairs. I encourage Gentle Reader to learn how to sharpen your own noble saws.
  3. Unknown Materials & Quality: As mentioned above, kaeba saw blades are made from pre-hardened, pre-sanded sheet steel (chemical content undisclosed) of uniform thickness supplied by rolling mills (nation of origin undisclosed). When your humble servant first inspected a kaeba saw maker’s plant around 2010, they were using high-quality, clearly-identifiable steel of known chemical composition produced by a reputable Swedish mill (specs and QC marks etched on the surface of the steel), but now that kaeba sawmakers have effectively conquered the handsaw market in Japan, the “bait and switch” principles taught by Harvard Business School and exemplified by McDonalds hamburglers have been fully implemented. Not unlike BS, B&S is an extremely profitable business management tool, one considered wise by some short-sighted business executives and those who can’t count past 20 without dropping their pants. Caveat emptor, my dear.
  4. Differential Heat Treatment: Although some Gentle Readers may be unaware of the importance of differential heat treatment in an excellent sawblade, much less the pros and cons thereof, kaeba sawblades lack the advantages of the differentially hardened plate found in quality, traditional Japanese (and Western) handsaws resulting in:
    1. Decreased toughness of the plate
    2. Increased springiness and resonant vibration in-use often harming precision;
  5. Taper Grinding: Being made of uniform-thickness sheet steel, the kaeba sawblade is not taper-ground resulting in:
    1. Increased binding and kinking in use. A kinked sawblade, of course, is irritating and destroys precision. It’s also less than worthless because it interrupts the user’s work as he replaces it, an inconvenience and expense the uninformed user typically blames on himself even though the true culprit is the inferior sawblade.
    2. Greater set is required to avoid binding and kinking, which equates to more energy and time expended to create more sawdust, a positive factor for weight loss, but not so much for efficient work.
    3. Greater tendency of the blade to wander in the cut increasing irritation while reducing precision.
  6. Sketchy/No Hammer Tensioning: Although some kaeba blades are tensioned between steel rollers in the same way circular sawblades are, the tensioned area in kaeba saws is a band across the length of the blade, and not the ideal oval shape sawsmiths typically produce by hand resulting in greater susceptibility to warpage/buckling as the blade heats up in use resulting in increased friction in the cut, reduced work efficiency, increased irritation to the user, and more damaged blades requiring replacement thereby increasing the profits of sawblade manufacturers, distributors and retailers. Another of Baldrick’s cunning plans?
  7. Less Precision: The precision achievable using kaeba backsaws such as dozuki is significantly less than that of high-quality hand-forged traditional dozuki backsaws for the following reasons:
    1. The back may not be straight;
    2. The back is not secured to the blade as securely permitting more slop;
    3. The plate has never been trued and may not track as precisely.
    4. The set of kaeba saw blades is decidedly excessive for precise joinery work.
  8. Rougher Cuts: Kaeba blades typically have greater set compared to traditional sawblades necessitated by their lack of taper grinding, making the saw cut less smoothly. In addition, uneven left-right set often encourages the sawcut to wander into the weeds.
  9. Landfill Stuffing: As mentioned in Advantage 4 above, like cat litter, plastic beverage bottles, and modern marriage, kaeba saws, are “use and toss” products, veritable landfill stuffing in-waiting. I will leave it to Gentle Reader to decide if this is good or not, but I am convinced kaeba saws find the transition from valued tool to rubbish lonely and emotionally damaging, which explains the increased demand for board certified metallurgical psychologists such as ton modeste serviteur.

Only Gentle Reader can answer the question of which type of saw is superior, but despite my sometimes negative observations listed above, I freely admit to liking and using both types in the context of “horses for courses.”

User Improvements to the Kaeba Dozuki Saw

Many moons ago I associated with a group of young, energetic and extremely pragmatic carpenters in Tokyo intent on finding solutions to deficiencies in modern tools anyone could put into effect. For instance, one item they studied to death was how to get the most from synthetic waterstones, a highly-successful bit of research IMHO.

Another tool they researched was the kaeba dozuki. While they didn’t propose any new, earth-shattering innovations, some of their techniques are worth employing.

Improvement No. 1: Side-jointing the Teeth

This first tuning technique is one that works on all handsaws and can especially help your kaeba dozuki saw cut straighter and more precisely, leaving a narrower kerf and smoother surfaces. This is traditionally performed using a file in the case of standard sawblades, but in the case of a kaeba dozuki saw with induction-hardened teeth, we need to use a harder tool and with more precision; Enter the Arkansas stone stage right.

You will need a new kaeba dozuki blade, a hard (not soft), flat Arkansas whetstone (novaculite) dimensioned approximately 8″x3″ (larger is OK but much smaller won’t work well), a piece of white copy paper, a can of light-weight spray lube such as WD-40, CRC5-56 (not PTFE), or brake cleaner, a relatively clean toothbrush, and a clean cotton rag. Please note that India stones, carborundum stones, waterstones, diamond plates won’t get the job done.

  1. Lay the paper down on a flat, stable, wooden board or workbench. Place the sawblade on top.
  2. Give the blade a light spray of lube.
  3. Gingerly place the hard Arkansas stone lengthwise on the blade parallel to the cutting edge, with one end hanging approximately 25mm (1″) off the toe end of the blade, one long edge resting on the blade, and the opposite long edge hanging off the blade about 6mm (1/4″) past teeth.
  4. Without placing any downward pressure on the stone, pull it towards the heel (handle end) of the blade, parallel to the tooth line, in a single smooth stroke until the end of the stone is hanging about 6mm off the heel of the blade. Slow or fast, it makes no difference, but I prefer slow. Just one stroke, mind you. The goal is for the stone to lightly abrade the sides of the tips of the teeth essentially “jointing” and bringing them all into line. In addition, and perhaps more importantly, even if your sawblade has perfectly uniform teeth, kaeba dozuki blades almost always have too much set, which this technique will reduce, improving the smoothness and precision of the cuts it makes.
  5. Turn the sawblade over and repeat steps 1~4. With this the stone will have made a single pass over both sides of the tips of all the blade’s teeth. In the case of blades with induction-hardened teeth, you may need to make 2 passes of the stone per side, but be aware that every pass reduces the useful life of the blade significantly. Also (and this is very important if you value your sanity), be sure to make the same number of strokes in the same manner to both sides of the blade.
  6. Take the blade outside and blast it with your can of spray lube to remove any particles of stone and metal left in the teeth. You may not be able to see this swarth (mixture of stone, steel and lube residue), but it is there, and if not removed, it will dull the blade during the first stroke in wood sure as eggses is eggses.
  7. Use the toothbrush and more spray lube to scrub the teeth to remove any remaining swarth residue.
  8. Spray the blade with lube or brake cleaner from both sides with the teeth pointing downward flushing any remaining swarth out of the teeth.
  9. Wipe the blade with the cotton rag from the blade’s back over its teeth. You don’t want the teeth to cut the cloth, or the cloth to catch on the teeth. If you observe any swarth residue on the cloth, repeat steps 6, 7 & 8. Do not use the saw until all the swarth is gone.

Tasting the Pudding

Now that the sawblade’s teeth have been right/left jointed, let’s test them to see if they need further persuasion.

You’ll need a piece of flat, knot-free softwood like pine with one straight/square edge, perhaps 150mm (6″) wide and 19mm (3/4″) thick. Use your marking knife and hardened square to mark a line on the wide face perpendicular to the straight edge. Clamp this board to your supporting bench or sawhorse with the line you just made hanging off the side.

With the saw’s edge angled about 30˚from the horizontal plane (surface of the board), begin a cut from the far end of the line. use a light touch and let the saw cut where it wants to cut. Does the saw cut a straight line, or does it tend to wander to the left or right?

You may not be able to tell from this initial test, but pay attention when using the saw to see if it tends to wander from the line. If it does, the teeth on the side of the blade it tends to drift towards may have too much set, in which case use the same stone and lube to joint the teeth on the offending side. Be very gentle because there’s a risk of making it worse.

Again, be aware that jointing the sides of the teeth means you will have to joint the top of the teeth more than usual next time you sharpen them reducing their length and the overall lifespan of the blade that much more. This is not a big loss for kaeba saws, but will reduce their lifespan.

Improvement No. 2: Tuning The Back

Straightening a kinked and/or twisty saw can be a little like wrestling the carp in the wood block print above. I don’t know the story depicted here, but I’m pretty sure it’s a scene in a kabuki play. The guy in middle with the sword is an actor named Onoe Tamizo playing a carpenter named Rokusa. The guy on the right with the ugly scowl is played by Banto Hikosaburo (no sword visible). The lady (?) on the right with the short sword is played by Onoe Eizaburo. These are all male names because men play the female roles in kabuki plays, and acting troupes were often related as they are now.

Dozuki saws have steel backs used to stabilize the thin blade and protect it from buckling. In the traditional saw this is a folded strip of steel that clamps over and tightly grips the back of the blade, much like Western backsaws. In the case of kaeba dozuki saws, however, the back cannot tightly grip the blade too tightly or it will be impossible to replace the blade, reducing the money, money, money, money, mo-ney the manufacturer needs Gentle Reader to contribute towards his purchase of that new Italian sportscar and the Greek vacation he promised two of his girlfriends (at the same time?).

The problem is that this necessary “tolerance” (aka “slop”) often allows the blade to wander more than is necessary. But what to do? I propose three useful techniques below for Gentle Reader’s kind consideration.

Deburring the Slot

The first item we need to check for is burrs inside the slot in the back. This is not a frequent problem, but it does occur.

Begin by removing the blade from handle/back, reversing it, inserting the nose or tail of the blade in the slot, and without cutting your hand, running it back and forth in the slot. This should give you a good idea if there any big burrs or restrictions in the slot. If you find any, mark the location on the back with a marking pen.

Next, and while it may imperil your extravagant income and glamorous lifestyle as an international hand model, run your fingernail inside the slot checking for burrs that might tend to tweak the blade this way and that.

If you detect any burrs, a skinny deburring tool might get rid of them. Be careful that bits of metal don’t fall inside the slot.

Or, you can fold a piece of wet/dry sandpaper (220 grit?) in half and run it back and forth in the slot where the burrs are hiding removing/smoothing them. Some of that spray lube might help. When doing this, once again be careful to prevent large pieces of metal from falling inside the slot. When done, thoroughly flush out any swarth and bits of metal with a few squirts from your can of spray lube or brake cleaner while swinging the handle like a helicopter rotor blade. I guarantee The Mistress of the Blue Horizons will neither understand the importance of this manly ritual nor appreciate the artistic spots it may leave on her walls and ceilings, so I suggest you perform it outside, with style and grace of course.

Straighten the Back

With the slot safely deburred, let’s next consider the back’s straightness. Obviously, if a saw’s back isn’t straight, the blade won’t be either, and the cut it makes will tend to wander. So you need to check the back, and if you determine it’s out of wack, correct it.

The back, being made of folded sheet metal, is not a precision-milled component, so please don’t expect perfection, and firmly quash any OCD persnicketiness.

With the blade installed, use a precision straightedge held against the sides of the back with a lightsource to check for bow and gaps. Be sure to check both sides. A steel straightedge like that of a combination square will work, but a thinnish beveled-edge straightedge like our 400mm stainless steel straightedge by Matsui Precision works best.

A feeler gauge may be helpful in evaluating any gaps.

Straightening the back is not something readily done with a hammer for a number of reasons, but we can bend it straight if we are careful. To do this, lay the saw, with blade attached (this is important), on a flat workbench top or board with the cupped surface facing up. Place a stick of wood under and perpendicular to the back at the lowest point of the cup. The thickness of this stick is key and will take some trial and error.

Place one hand pressing down on the end of the back where it joins the handle, and the other hand on the far end. Press down slowly and carefully, bending the back without taking it past the yield point where the back will permanently bend. The back should rebound when you remove pressure, returning to its original shape without permanent deflection. Repeat this until you develop a sense of the pressure required to reach, but not exceed, the “plastic limit” of the back. You may need to add to the thickness of the stick used to spring the back.

When you have a good sense of the pressure required to just reach the plastic limit, press down on the back again with a little bit of extra pressure causing the back to permanently bend just a tiny bit. No pro-wrestling moves, please. Check the back with your straightedge to determine any improvement in straightness.

The same bending action can be achieved by placing the back, with blade attached to keep the slot from closing up, in a vise with padded jaws. Don’t clamp the saw in the vise tightly, but leave a little gap, and press on the back where it joins the handle, not the handle itself. This technique works well, but since it’s a bit more difficult to feel the plastic deformation of the back, and to control the point of flexure, it requires more self control. Please keep that darned inner badger under tight control.

If the back is snaking this way and that (very unusual), you can try the same technique in various directions.

Check progress with your beveled straightedge frequently.

If this doesn’t work, and your dozuki still refuses to make high-precision cuts, bite the bullet and replace it.

Tuning the Slot

Now that the blade slot is deburred and the back is fairly true, the next step is to determine if we need to improve the gripping pressure of the back on the blade.

This is a difficult job because we need the back to apply enough pressure on the blade to hold it in place without wiggling, but too much pressure will make it difficult to remove and replace the blade without damaging it. So begin by checking the fit of the blade in its slot.

Insert the blade and, while holding it under a strong light, push it right and left paying attention to any gaps that may open between blade and back.

If you discover any significant gaps, mark the locations on the back with a marking pen. A feeler gauge may be helpful. You will need to judge if the blade wiggle caused by these gaps is enough to warrant an attempt to close the gaps.

There are two ways to close any gaps; Both are risky. The first is to use a small hammer to tap tap tap on the back. The second is to use a vise or a C clamp to close the slot. Either way, be sure the blade is in the slot when you execute.

This concludes our tome about handsaw history, advanced business management techniques, rodent cuisine and modern marriage. I hope you found it informative.

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.

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Japanese Exchangeable-blade Handsaws Part 1 – History & Varieties

When God means to punish a man He sends him stupid friends and clever enemies.

Joe Abercrombie, Best Served Cold

Introduction

Gentle Readers are probably familiar with the modern mass-produced mass-marketed exchangeable-blade handsaws made in Japan. In this first part of a two part series we will briefly examine the history of how these saws came to be, how they are manufactured, and the market forces that made them so popular in Japan and even overseas.

In Part 2, to be published later, your most humble and obedient servant will list pros and cons and share some techniques for improving their performance.

Gentle Reader may already be aware of these saws and even own and use them at work daily, but in this article your humble servant will share details about them not available elsewhere. I pray it proves informative, or at least entertaining.

Terminology

In the Japanese language the type of consumer-grade handsaw I mentioned above with blades that can be removed and reattached to a handle mechanism are called “kaeba nokogiri” (kah/eh/bah nokogiri 替刃鋸) meaning, of course, “exchangeable-blade saw.” From this point forward I will call them “kaeba saws” for brevity. They have entirely replaced traditional forged handsaws in Japan for good and valid reasons, and indeed are popular throughout Asia as well as Western countries too.

So let’s begin this adventure by considering the history of this new version of an old tool that shook the handsaw world like a terrier does a rat.

Historical Background

In the late 1970’s the kaeba handsaw appeared in the Japanese market changing everything.

I’m not sure who first developed the concept, but there’s no doubt it was inspired by the convenient and highly-profitable bits and blades used with powertools. The first automated equipment for making these sawblades was developed by a 150 year old company located in Sanjo, Japan that shifted their traditional saw sharpening business to producing and selling CNC saw sharpening machines. Later, inspired by automated circular-saw blade production techniques, they went on to develop CNC machinery to fabricate handsaw blades in an automated production line.

Production Methods

The manufacturing process begins with materials, of course. The primary material is pre-hardened sheet steel sanded to uniform thickness in rolling mills, and delivered to the blade manufacturer in large, heavy rolls. This product means the blade manufacturer doesn’t have to sort, forge, heat-treat, stress-relieve, or taper-grind the steel. In fact, he couldn’t even if he wanted to.

As this roll of sheet steel is unspooled into the production line, CNC machines cut and deburr the blade blanks, punch the teeth, and shape and sharpen them with special abrasives, after which set is applied by machine. And unlike traditional hand-forged fixed-blade saws, the plates are not forged, taper-ground or heat treated by the saw manufacturer at all. This is an important distinction to those who know saws from shinola.

Some but by no means all such blades are tensioned between two steel rollers in imitation of the techniques used during the manufacture of circular saw blades.

Most kaeba manufacturers induction-harden just the tips of the teeth of some blades for extra durability as the blades are fed between, and instantaneously heated red hot by, electrically-charged copper blocks, then immediately quenched in coolant spray after exiting the induction blocks leaving them a darker oxidized color. These blades cannot be sharpened by hand as the teeth are harder than files.

Handles

Kaeba saw’s handles are sometimes made of wood, sometimes of plastic, and sometimes of rubber over plastic. The blade is secured to the handle by metal mechanical widgets and sometimes screws integral to the handle. The blades can be quickly and easily changed encouraging consumers to do so frequently, but each manufacturer’s blades will fit only their proprietary handle locking the consumer into buying proprietary replacement blades, much like printers and ink/toner cartridges, because as the O’Jays sang on Soul Train, it’s the blade that makes the money, money, money, money, mo-ney, but it’s the handle that drives market share.

And with labor costs to produce such a handsaw a single digit percentage of what’s required for a traditional handsaw, the few manufacturers of kaeba saws find it difficult betimes to wade through the mountains of mad stacks laying about.

With the production technology perfected, compatible materials available, and CNC machinery in the hands of a few manufacturers, it was only a hop skip and a jump to widespread sales of kaeba handsaws, and if I may paraphrase my old carpenter foreman Uglúk, it looks like rats are back on the menu, boys.

Some prefer their rodent roasted on rye with horseradish sauce, but I prefer mine sauteed with a drop o’ Tabasco Sauce, or as Bert suggested, maybe even a floater for delicately piquant flavor! What about you?

The Societal Impacts of Kaeba Handsaws 替刃鋸の波及

I mentioned above that this new type of saw changed everything. Of course, that’s a bit of an exaggeration because babies still love boobies and politicians graft, but indeed some things changed drastically in Japan.

The first big change the kaeba handsaw wrought was putting nearly all the traditional sawsmiths in Japan out of work in a matter of a few decades. Indeed, the number of sawsmiths still forging traditional saws full-time nowadays can be numbered on the fingers of one hand after a manicure using a tablesaw.

The second domino was the near destruction of the saw handle industry. As the demand for exchangeable-blade handsaws ramped up, the production of traditional handsaws, along with the need for traditional handles, crashed.

You see, exchangeable-blade saws have patented brand-specific wooden handles with integral metal mounting plates/screws/clips to which the specific blade-maker’s replacement blade is attached. The maker of each brand of exchangeable-blade handsaw subcontracts the production of their handle to specific suppliers, and since the producers of handsaws are now few, so are the handle suppliers. Sadly, your humble servant is aware of only one, and occasionally two producers of traditional handles still operating. I believe they still have all their fingers but I’m concerned one gentleman’s liver has seen better days.

Just when it looked like things couldn’t get worse, the third domino fell-over and crushed the saw sharpening trade. While many kaeba saws can be resharpened, some cannot be economically resharpened at all because their teeth are induction-heat-treated to be harder than sawfiles. In fact, while it’s usually a little cheaper to have even a kaeba sawblade professionally sharpened rather than purchasing a replacement, buying a new sawblade and tossing the old one is quicker, more convenient and obviates the need to carry spare saws to a jobsite because thin, lightweight replacement sawblades will suffice. In any case the jobs of saw sharpeners (metateshi meh/tah/teh/she 目立て師), like those of sawsmiths, handlemakers, wheelwrights, and honest climate scientists have been practically eliminated.

The one overarching societal lesson one can take away from this is that technological advances always have and always will engender painful changes in every industry in the world, and the case of the Japanese handsaw industry only confirms that one can either ride the train of technology sipping tea and eating pringles in comfort as it rolls along, or grease the tracks as it runs one over. Just ask the once mighty Eastman Kodak company of camera and film fame if ‘taint so.

A similar progression occurred within the saw manufacturing industry in the West, but instead of the changes stemming from product innovation, the causes were quality adulteration, active neglect of customers needs, and abandonment of unparalled tradition. Welcome to the Harvard School of Business Management’s model of “profit through disruption” in action. I hear they’re looking for a new university president.

An American Handsaw Maker

To this point we’ve taken a shallow look at Japanese handsaws, especially the impact of the kaeba variety on Japanese markets, but highly intelligent Gentle Readers (could there possibly be any other kind? absolutely not!) may wonder how in heck these strange Japanese products managed to make such profound inroads into Western markets, so a few points about a well-known American saw manufacturer may prove instructive.

Gentle Reader may recall that the famous American handsaw manufacturer Henry Disston (1819–1878) was born in England the son of a designer and manufacturer of lace-making machines and immigrated to the USA in 1833 along with his father and sister. His father died three days after stepping off the boat. Tough luck.

Being a determined and diligent young man, Henry apprenticed himself to a saw company in Philadelphia, Pennsylvania. In 1840 he went independent, and after some lean years building a reputation for quality, he founded the Keystone Saw Works there in 1850. After the American civil war his son Hamilton joined the business and Henry changed the company’s name to Disston & Son, and later to Disston & Sons. At its peak Disston & Sons was the largest and most productive saw manufacturer in the world with 8,000 direct employees working on 300 acres.

At the time he established the Keystone Saw Works, nearly all tool steel used in North America was imported from Great Britain. This was a serious impediment to growth so Henry established the first crucible steel mill of consequence in the Americas to supply steel for his products and to support the war effort, and although other more famous, ruthless individuals falsely took credit for developing steel production in America, they were originally only Henry’s customers. For the next 25 years, the Disstons were among the largest producers of quality tool steel in the world outside England.

Interestingly, American consumers at the time were absolutely convinced that only Birmingham, England could make quality tool steel, so while other American sawmakers imported their steel from England, D&S used their own steel, avoiding the high import tariffs of the time. But to avoid the stigma of being seen as a “colonial product,” for many decades the acid-etched engraving on Disston & Sons’ sawblades included variations of the words “London Spring Steel” intimating that more prestigious British steel was used. Interestingly modern chemical analysis suggests that D&S’s tool steel was at least as high-quality as that imported from Britain at the time.

The first handsaw I owned as a young man was an antique and terribly rusty D&S D-8 thumbhole rip saw missing a handle (but with partial screws) I found languishing in a joint compound bucket in the back of a Las Vegas pawnshop. My penny-pinching carpenter father said it could be restored to be a better saw than I could buy new, and at $3 and a lot of elbow grease, the price was right and so was he. After derusting the blade, making a handle from a piece of scrap walnut, and reworking the teeth several times until I got the nack, that antique D-8 became an excellent handsaw, far superior to the new Disston saws still available at the time. My son owns it now.

A classic 28″ Disston D-8 swayback rip saw with a 2 hand thumbhole stock. Not my rescue saw but close.

The first point I want to make in this section is that by the time I was old enough to want to own a handsaw, the circular saw ruled the construction industry in the West (but not yet in Japan) and most younger carpenters neither owned a decent handsaw nor could care less. As a result of these market changes, the production and sale of handsaws became less profitable, the quality of those available became shamefully degraded, and instead of increasing production efficiency, and/or innovating like Japanese saw companies did, D&S did a double doodoo on quality, then lay down to be eaten by vultures. Other than a few tiny, recently-established boutique backsaw makers, the once-mighty American handsaw industry is now as dead as decency.

My second point is that this shameful degradation and subsequent abandonment of a once huge and profitable American industry fomented despair among Western woodworkers who needed quality handsaws but couldn’t procure them new anymore forcing many, like your humble servant, to haunt flea markets, pawnshops, and later Ebay for old handsaws (including Disston & Sons products) and to even purchase tools imported from Japan back when Japan’s reputation for quality was not as shiny as it is now. These forsaken and “disrupted” woodworkers, hungry for better tools, were the primary reason medium-quality but very sharp Japanese crosscut handsaws first became so popular in the USA. And when Japanese kaeba saws became available later, overseas markets snapped them up like the proverbial duck on a June bug.

FYI, the Disstonian Institute website has some interesting information about Disston & Sons those interested in history may enjoy.

As an aside, I noticed that Disston, now the Chinese holesaw maker, is offering a newer version of the D-8 26″ swayback rip/crosscut handsaw exclusively on Amazon. It looks shiny! The country of manufacture and local content is not listed anywhere, but probably not the USA and definitely not Philly. The video on their website almost made your unworthy servant spew chunky chunks. Consider yourself warned.

Let us next shift our attention back to the kaeba saw and consider the first and most popular such handsaw, as well as some other popular varieties.

Dozuki Kaeba Handsaw

The dozuki handsaw was the first Japanese kaeba saw to become popular overseas, perhaps initially attracting attention because it vaguely resembles the petite “gents” back saws once popular with amateurs. The dozuki is a thin crosscut backsaw (a single-edged handsaw with a steel or brass stiffener attached to its back) that cuts on the pull stroke.

The name is pronounced dough/zoo/key and is comprised of two Chinese characters: “胴” pronounced “dough” meaning “trunk” as in the trunk of a tree or the human torso, and 付き pronounced “zookey,” a verb meaning “to attach or make.” To the best of your humble servant’s understanding most Western woodworkers are unaware of the name’s meaning or the saw’s specialized purpose but nonetheless they use them for everything but spreading jam on toast (marmalade gums up the teeth terribly). The name refers to the job of cross-cutting the shoulders of tenons, but not the cheeks, which is a job for the specialized “ hozohiki” rip saw.

A 210mm dozuki crosscut saw with fine teeth for precision work. The manufacturer calls it a “kumiko” saw after the narrow slats found in traditional decorative joinery such as shoji and ranma. The teeth are not induction hardened. The fit between back and blade is pretty darn good and it makes excellent cuts, but the teeth have too much set for the highest-quality work.

In the case of joinery, furniture, cabinetry, and fine architectural woodwork, well-made mortise and tenon joints are essential to the appearance and even the strength of the finished product. And since the shoulder is the only visible part of most mortise and tenon joints, shoulder appearance is important.

Cutting tenon shoulders in a craftsman-like manner in the Japanese tradition demands not only a good eye, a good saw, and a skilled hand but speed, because the craftsman is expected to saw deftly, precisely and cleanly to the layout line the first time every time, all day long. This differs from the inefficient, amateurish methodology for cutting tenons in cabinetry and joinery as taught by the Holy Masters of Woodworking in the West who lack adequate saws and/or skills and shamefully advocate cutting wide of the layout line and sneaking up on it with chisels and planes. How embarrassing.

A quality dozuki saw is extremely effective at making these cuts. To do so it must be able to make a straight, precise, smooth cut right to a final layout line every time without wandering off into the weeds and without having to use a paring chisel or shoulder plane to obtain a clean, square, straight shoulder. Accordingly, it must have a thin, true plate that won’t produce excess friction, nor buckle, oil-can, or bind as it heats up, and fine, uniform teeth with minimum practical set. It must also have a lightweight but rigid steel back that effectively keeps the blade’s plate true, protects it from buckling, and discourages it from weedy adventures.

Kaeba dozuki saws come in various lengths ranging from 150mm to 240mm. TPI varies with maker. Zetsaw by Okada Industries is my favorite kaeba brand and makes some with induction-hardened teeth that can be made extremely useful with the modifications I will share in Part 2. FYI, your humble servant does not sell Z-saws and has never received free (or even discounted) samples, nor been wined, dined laid or paid to promote them.

Interestingly, even before the development of the exchangeable-blade kaeba saw, the Japanese dozuki saw was used in the West for cutting dovetails, a job which requires occasional crosscuts but frequent rip cuts, something the hozohiki saw does much better. In any case, that Western woodworkers ended up preferring the Japanese dozuki saw for even rip cuts may give Gentle Reader an idea about the comparatively adulterated performance of readily-available Western dovetail saws from the 1970’s onward.

The kaeba concept has been expanded to include useful saws of many shapes and sizes, some of which your humble servant owns and uses, especially when there is a risk of damaging one of his professional-grade fixed-blade handsaws.

Let’s next consider some popular varieties of kaeba saws other than the dozuki and hozohiki.

Kaeba Crosscut/Rip Saws

The best selling Japanese handsaw both domestically and internationally is the standard single-edged (“kataba”) carpenter’s crosscut saw. These come in various lengths, shapes, and with various types of teeth. They are handy in the shop, and I always have one or two of these on hand when working in the field, especially when cutting EWP (engineered wood products) which I refuse to allow my hand-forged saws to even touch no matter how much they wiggle and whine. If you need to cut plywood or other EWP, these saws are a must-have IMHO. More on this subject in Part 2.

A 265mm kataba crosscut saw with hardened teeth by Zeton owned by your humble servant. The blade has seen a lot of abuse and neglect. It has a paulownia wood handle still wrapped in plastic with the pricetag still attached.
A 7sun (210mm) crosscut saw by Zeton missing a couple of its induction-hardened teeth. It has a soft paulownia wood handle that has seen better days. Hinoki would have been a better wood in this case.

But the usefulness of kaeba saws is not limited to woodworking and sandwich making only, oh no. I carry a 333mm (13″) kaeba formwork saw with a lightweight plastic pistol-grip handle when hunting because no other tool I know of is so light, so compact, and can cut so much wood so quickly.

A special-use kaeba saw I am fond of, with two of its blades shown. The handle (a Zeton product) is made of fairly lightweight but tough plastic, but its most valuable feature IMO is its short length which makes it fit nicely inside toolbags and backpacks. The 300mm blade, handle, and a wooden scabbard I made to fit, goes in the toolbag I take to jobsites. I have a plastic scabbard for the 333mm saw which I strap to my backpack when camping and hunting. Much lighter and more compact than an axe.

The Silky brand arborist’s saw blades are excellent for this purpose too if you ditch the heavy rubber handle and gaudy scabbard.

Ryouba Double-edged Kaeba Saws

This style of kaeba saw combines a rip saw and a crosscut saw in one exchangeable blade. I own one 270mm kaeba ryouba saw with induction-hardened teeth I like well enough, but I still prefer fixed-blade ryouba saws. I daresay most people can’t tell the difference.

A 270mm ryouba double-edged saw with hardened teeth by Fujiwara intended for interior installation work. The blade retention bar can be seen projecting from the center line of the handle. I’m unsure if this saw is still being produced
The same 270mm ryouba saw disassembled showing handle, blade, and wire retention clip. The two bent tabs at the end of the sprung retention bar fit into the two slots in the blade when assembled.
The same 270mm ryouba kaeba saw showing the wire retention clip used to secure the two tabs that lock the blade in-place. Notice the blue-black discoloration of the sawteeth tips typical of induction-hardening.

Saws retailers here in Tokyo tell me that sales of kaeba ryouba saws have dropped off dramatically the last few years probably due to increased prefabrication and LGS metal studs replacing wood and LVL (laminated veneer lumber) framing for interiors such that rip cuts in wood in the field are seldom necessary. I believe this increase in the use of pre-manufactured components is in part due to three inter-related factors: (1) Rising construction costs; and (2) High demand in the construction industry; and (3) An aging workforce resulting in a decrease in available manpower in the construction industry making it difficult to meet customer demand. I fear the current attitude of Japanese women about bearing and raising children will prove disastrous for the nation soon as you can say “Bob’s not your uncle.”

Teflon Coated Blades

Zetsaw sells some of its blades with a PTFE teflon coating which I have found to be very effective in reducing friction and preventing sap from accumulating when cutting some softwoods. Makes a great egg turner too.

An 8sun (235mm) rip saw with hardened teeth and teflon coating by Zeton. This is an exceptionally useful saw.

The Adventure Continues

In the next installment in this operatic series about the funky love of money, fine dining and handsaws we will examine the advantages and disadvantages of kaeba saws compared to traditional fixed-blade saws, and explain simple techniques Gentle Reader can employ to supercharge your kaeba saws.

But in the meantime, since the IMF, EU and UN are on the verge of outlawing backyard vegetable gardens at the same time they are taking by force and sacrificing the land of European farmers on the alter of the religion of “Climate Change,” (how did that work out for Sri Lanka?) all while increasing pressure on others (regular people, but not the bureaucrats/elite) to substitute bugs for meat (I kid thee not), I would appreciate Gentle Reader sharing any tasty recipes you may have for crispy, crunchy low-fat rodent dishes in the comments below. I need to broaden my culinary repertoire in preparation for more societal “disruption,” you see.

YMHOS

I ain’t gonna eat no bugs!

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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.

To learn more about and to peruse our tools, please click the “Pricelist” link here or at the top of the page. To ask questions, please the “Contact Us” form located immediately below. You won’t be ignored.

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, treacherous X, Harvard University, or H. Clinton’s IT dude and so won’t sell, share, or profitably “misplace” your information. If I lie may someone bukkiri my neck.

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Japanese Handsaws: The Bukkiri Gagari

A 320mm (“shakuni”) bukkiri gagari handsaw with a kiri wood handle resting on your humble and obedient servant’s atedai workbench

Socialism is the philosophy of failure, the creed of ignorance, and the gospel of envy.

Winston Churchill

The goal of socialism is communism.

Vladimir Lenin

Thank you for visiting the C&S Tools Blog! This article will be a show and tell about a couple of unusual saws of a type not well know outside Japan. For that matter, they are no longer common inside Japan.

The Bukkiri Gagari Saw

The three saws pictured in this article are of a type of Japanese handsaw called a “bukkiri gagari.”

Terminology

Let’s begin with the second word in the name, “Gagari,” (gah/gah/rhi) which refers to a larger rip saw intended for rougher work. Usually forged heavier and stiffer than standard handsaws, these were once standard tools in every Japanese carpenter’s toolbox, used for ripping boards and cutting joints in timber frames. The teeth are made large to quickly eat lots of wood, but when properly sharpened, given the right set, and used correctly, they will make smooth cuts indeed.

Your humble servant has only seen the word gagari written using phonetic “hiragana” characters which are derived from Chinese characters but do not have any inherent or historic meaning, so while I can’t guess where the word came from, in exchange for a delicious chocolate chip cookie (with a glass of cold milk, please) I might be so bold as to suggest it came from the rough sound large rip saws make when ripping thinner boards.

Likewise, I’ve never seen the modifying first word, “bukkiri” (book/kee/reeh), written using other than hiragana, but even without a cookie bribe I can guess that “bukkiri” is a modification of the word “bukkiru,” which means to “chop off” something, for instance the head of a fish or an especially-corrupt politician. In this case, I believe it refers to the pointed tang having been chopped off short. So a bukkiri gagari is a larger rip saw with a shortened tang and an angled “shumoku” handle.

The Shumoku Handle

A shumoku mallet for striking small bells

The handle is especially unusual so let’s consider it next. The skewed handles in the photos in this article are called a “shumoku” (shoo/moh/kuh) 撞木 handle.

Shumoku is an interesting word. The Chinese character “Shu” 撞 means bell, while “Moku” 木means wood. In other words, a shumoku is a piece of wood for ringing bells. The image to the right is of a wooden mallet used to strike small tabletop bells during Buddhist ceremonies.

The shumoku in the video at this LINK is a tad larger, being motivated by a group of 17 jolly monks in a bell-ringing ceremony at Chion-in Temple (知恩院, Monastery of Gratitude, Jodoshu-sect) in Kyoto. Said to be the largest bronze bell in Japan, it seems to take a lot of work to make it sing!

I have no clue why this word is used for a saw handle, and those in the industry I’ve asked didn’t either. A mystery. Based on my long years of experience reading and writing in the Japanese language, it seems likely that the woodworkers that made and used this style of handle back in the mists of time gave it a name with a pronunciation similar to shumoku back in the days when few commoners could read or write, and centuries later when the came time to write the word using Chinese characters, someone decided to use the “bell wood” characters just to poke fun at the monks in their funny dresses (ツ).

Despite what those who like to portray the Japanese language as highly cultural and absolutely logical suggest, I can assure Gentle Reader it contains many instances of such strange “assignments,” just another reason why the written language is too often confusing.

Long, straight handles with oval cross-sections are more common in Japan, and certainly better known outside Japan. And the straight handle makes accurate cuts easier because one can readily sense if the blade wanders from a straight line in the cut. But, in some cases, the straight handle has three disadvantages. First, the handle’s length sometimes gets in the way when making long strokes in the tight spaces where carpenters are sometimes required to work, whereas a saw with a shumoku handle is shorter, and is easier to use from various angles, for example, when cutting a tenon or a housed dovetail from under a beam. Second, the straight handle depends on a high-friction grip by both hands to motivate powerfully, whereas the shumoku handle does not. And third, it’s more difficult to use as powerfully as the shumoku handle due to the angle of the user’s hands in-use.

Here’s are a Link to a video of a guitar luthier using a bukkiri gagari saw.

Two Examples of Bukkiri Gagari

The photo above shows two saws: the antique 320mm shakuni (1.2 shaku) bukkiri gagari as well as a longer 355mm “shakusan” (1.3 shaku) bukkiri gagari saw hand-forged and hand-sharpened for your humble servant by Nakaya Takijiro Masayuki, with teeth especially shaped for ripping hardwoods. A most excellent saw.

The shorter saw is over 150 years old, and according to the blacksmith’s hand engraving on the tang, was forged from “Tougo Reigo” steel, aka “Togo steel,” a British product made by the Andrews Steel Works and first imported into Japan by an officer who once served under Admiral Togo in the Japanese Imperial Navy and who borrowed the name of the famous military leader.

It’s a great saw, one your most humble and obedient servant has used frequently since purchasing it at a flea market in IIdabashi Tokyo many decades ago. I like the color it presents, the control it provides, and the compact size, but the teeth are little on the hard side as evidenced by a crack in one tooth. Togo steel is well-known for being on the brittle side.

The shumoku handle attached to the Togo steel saw is one your humble servant made from kiri wood with mulberry wood inserts and a black persimmon retaining wedge. The inserts keep the blade’s tang from wearing out the soft kiri wood, and the wedge makes it easier to remove the handle for transport. It’s fancier than necessary, but I had fun making it. Another way to secure a shumoku handle is with a dovetail wedge inserted from the side, but I don’t like the weaker nature of this style, nor the feel of the wedge in the hand.

Gentle Reader will notice that the straight tang of the shorter saw has been cut off (“bukkiri”) square by the original owner long ago, and that the back of the blade curves away from the cutting edge. This curvature is standard for rip saws.

The longer 355mm saw, by comparison, has a shumoku handle I made from tougher Japanese white oak with a more-or-less rectangular cross-section and is secured by friction alone.

The blade of the Takijiro saw is more-or-less straight, lacking the curve towards the end, and instead of the tang being straight it’s curved downwards in the direction of the teeth. This is not a standard blade converted into a gagari by chopping the tang short, but was planned to accept a shumoku handle from the time it was just a spark glowing in Takijiro’s forge, making it a dedicated, professional rip saw. Takijiro shaped this saw for me after one his master forged for a temple carpenter many decades ago, a craftsman I met at his workshop, and who gave me the opportunity to use, and fall in love with, his saw.

Please don’t tell my other saws I said this because they tend to be anthropomorphically jealous, and while saw cuts seldom make hearts bleed, they can make fingers fly.

Converting a Rip Saw to a Bukkiri Gagari

Gentle Reader can readily convert a standard Japanese rip saw into a bukkiri gagari by cutting the tang short and making a shumoku handle, as is the case of the shorter saw in this article. The longer style saw is not available new, although Takijiro has forged a couple of them over the years for our Most Beloved & Patient Customers.

While this article has been about dedicated rip saws, some craftsmen convert crosscut saws in the same way.

A safety warning is called for here, however, after all, they don’t call it the “nanny state” for nuttin. If you add a shumoku handle to a standard saw blade, be sure to at least cut off the pointy end of the tang. Otherwise, you’re likely to find your chest and/or arm leaking red sticky stuff compromising your color-coordinated woodworking togs, a simply devastating fashion faux pas.

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

YMHOS

A bukkiri gagari rip saw This is one of a matched set of rip/crosscut saws custom-forged by Choujiro (Azuma-san) for a temple carpenter who never picked them up. Notice the curved back peaking towards the end, 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.

To learn more about and to peruse our tools, please click the “Pricelist” link here or at the top of the page. To ask questions, please the “Contact Us” form located immediately below. You won’t be ignored.

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, treacherous X, Harvard University, or H. Clinton’s IT dude and so won’t sell, share, or profitably “misplace” your information. If I lie may someone bukkiri my neck.

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Kiridashi Kogatana Presentation Box

May it be a light to you in dark places, when all other lights go out.”

J.R.R. Tolkien, The Fellowship of the Ring

he title of this article references two things: A little knife, and a little wooden box, both uniquely and traditionally Japanese.

The Knife

The knife in question is called a “kiridashi kogatana” (kee/ree/dah/she koh/gah/tah/nah)) or just “kiridashi” for short. Your most humble and obedient servant has written about this Japanese woodworking and general utility knife at great length in this article: The Kiridashi Kogatana Knife.

Kiridashi are Japan’s traditional utility, carving and woodworking knife. Indeed, until about 30 years ago, every school child in Japan was required to have a little one in their school bag for sharpening pencils, cutting paper, carving wood, and many other classroom tasks. But it has always been a serious tool for serious work by adults, one owned and used daily by nearly every craftsman in the country for centuries, at least.

But what are the advantages of a plain, flat, thin knife like this? A good question, one that most Westerners who haven’t trained in Japan naturally ask, and one that deserves a good answer. So let’s list some.

  1. Sharpness: Just as our chisels and planes, the blades of our high-quality, professional-grade kiridashi are of hand-forged laminated construction with a hollow-ground ura which makes them the easiest and quickest little cutters in the world to make frightfully sharp. And don’t forget, the love of sharp things is deep in the Japanese blood. You may find the articles at the following links amusing: In The Blood, Kireaji
  2. Carry and Storage: Kiridashi are easy to store and carry because they are flat and thin. Hardware stores sell cheaper versions of these little cutters with wooden scabbards, but this makes them bulkier. Our kiribako boxes are perfect for safe storage.
  3. Precision: It’s easier to make fine, precise cuts with a kiridashi than a thick, double-beveled Western-style knife with wooden scales because the flat, thin blade provides a better view of the work, provides better sensory feedback, and with fingertips located safely closer to the cutting edge, improved control.
  4. Cost effective: The kiridashi is the very essence of a cutting tool with no frills, no handle, and no expensive surround stereo system, just a simple, easily sharpened and fiercely-sharp blade.

Of course, kiridashi can be purchased with wooden handles and full wooden scabbards, or the user can make one to his taste easily enough. Your humble servant has made scabbards for those kiridashi he brings to jobsites for the extra protection they afford during transit, but they aren’t otherwise necessary and offer no advantage in the workshop, where I use a bit of cardboard as protective sheath instead.

So that explains the “Knife,” part of this article’s title, but what about the “Presentation Box” part? That’s next.

The Box

Being so popular in Japan, there is an extremely long history here of gifting better-quality kiridashi kogatana knifes to friends, families and fellow workers who use them. In fact, those procuring a kiridashi as a present have historically purchased them with a special presentation box of a type called a “kiribako” made of a wood much loved in Japan called “kiri ” (paulownia tomentosa). These little boxes typically have handwritten calligraphy on the lid describing the contents.

Regarding kiribako, It’s not an overstatement to say that one cannot fully understand the Japanese people until one understands kiri wood and kiribako.

Kiri trees have large leaves and beautiful flowers, grow extremely quickly, and produce a lightweight fragrant wood Japanese ladies love for cabinetry and chests used for storing clothing. Indeed, it was once common for fathers to plant a kiri tree at the birth of a daughter, and have the wood of the same tree made into a dowry chest or cabinet for her marriage when the time was right.

Due to popular requests going back years, we now carry kiribako boxes with hand-written calligraphy designed to fit our hand-forged kiridashi kogatana knives. They make excellent gifts and presentation pieces. And they’re not at all expensive.

Our boxes are solid-wood traditional construction, made in Japan by a Japanese specialist box-maker located in Niigata Prefecture, with a tight-fitting slip-on lid. They also come with the characters “Kiridashi” written by hand in ink on the lid along with the blacksmith’s name (Mr. Masuda) and his personal chop. Inside the box is a stamp that says “Shirogami” referring to the type of steel Mr. Masuda uses to make our kiridashi.

Given some time, and at no additional cost, Beloved Customers can request personalized calligraphy, such as the recipient’s and/or presenter’s name, the occasion, and even a date, in the Japanese language of course.

If you’re looking for an unusual, extremely traditional and classy gift for someone that likes beautiful, useful, sharp tools, this might be just the ticket. You won’t find them anywhere but C&S Tools. If you’re interested, please see the pricelist at the link below. To contact us please use the form below.

Pricelist

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 to find our products 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 or fascist facebook and so won’t sell, share, or profitably “misplace” your information. May all my kiridashi chip and break if I lie.

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The Challenges of Professional-grade Japanese Chisels

Perfection is a necessary goal, precisely because it is unattainable. If you don’t aim for perfection you cannot make anything great, and yet perfection is impossible.

Leonard (the cutter, not tailor) – The Outfit (2022)

We occasionally hear of people (not Beloved Customers, of course) complaining about Japanese chisels. Like much idle opinion expressed on the internet, this squirts and bubbles forth from a few vocal amateurs lacking real experience or skills, but it’s undeniable that, compared to the sharpened screwdrivers sold as chisels in Western countries nowadays, a little special knowledge, extra diligence and some actual hand skills are necessary to meet the challenges of professional-grade Japanese chisels.

In this article your humble servant will list some challenges one may face when first learning how to use and maintain Japanese chisels, and will suggest straightforward solutions for he who has ears to hear. But, because nothing except a movie studio executive’s reserves of morality exist in a vacuum, allow me to first provide some background about the way our hand-forged chisels are made, as well as the division of labor between the craftsmen involved, and explain how this influences modern attitudes among professional craftsmen.

Terminology & Relevant Links

The terminology used in this article may be unfamiliar to some, so to avoid confusion, allow me to immediately clarify four of them. In addition, the articles at the links below contain relevant information you may find useful.

“Ura” refers to the entire side of a Japanese chisel’s blade opposite the surface with the brand, not including the neck, of course.

“Uratsuki” is the hollow-ground depression at this same surface. This surface is tastefully black in our chisels. Others prefer this area to be polished.

“Lands” refers to the planar, polished surfaces at the ura surrounding the hollow-ground uratsuki on four sides.

“Itoura” is the most important of the four polished lands (itoura, side lands, and neck land) surrounding the uratsuki, being located immediately adjacent the cutting edge and forming one half of it. It’s important because, without it, the blade won’t cut.

The articles at the following links may prove informative, or at least amusing.

The Story of a Few Steels

The Ancient Art of Hand Forging

Sharpening Part 6 – The Mystery of Steel

Sharpening Part 7 – The Alchemy of Hard Steel

Sharpening Part 8 – Soft Iron

Sharpening Part 9 – Hard Steel & Soft Iron 鍛接

Sharpening Part 10 – The Ura

Professional-grade Chisels

Setting-up Japanese Chisels

Chisel Production

Beloved Customer has probably visited neither a modern tool factory nor a traditional chisel smithy, so a brief summary of the steps our blacksmiths employ in producing a hand-forged, high-quality, professional-grade chisels may provide useful insight.

Please note that the hardware store-grade Japanese chisels mass-produced for export that Westerners are accustomed to are not produced this way, and their performance suffers accordingly.

The Smithy

Our chisels are handmade by either single blacksmiths, or master & apprentice blacksmith shops, or father & son smithies using mostly old equipment, except for Mr. Usui of Sukemaru brand pictured below who works alone nowadays, has an engineering degree, and loves precision equipment.

Mr. Usui Forging an atsunomi chisel
Nakaya Takijiro (sawsmith) at his forge
Nakaya Takijiro’s forge, originally made for forging swords
Mr. Nakajima’s workshop
Mr. Nakajima, chisel blacksmith (ret.) in his workshop

Materials

The process begins with materials.

Nowadays, the blacksmith purchases processed iron and steel from wholesalers in ready-to-use strips. In the case of C&S Tools’ chisels, our blacksmiths use Hitachi Metal’s Shirogami No.1 steel exclusively along with a variety of low-carbon steel/iron called “gokunantetsu” 極軟鉄 meaning “extremely soft iron.” Neither of these products are currently being produced.

With materials in hand, the blacksmith will use his forge fired by gas and charcoal and fed forced air by an electric blower to help create the necessary atmosphere and high temperatures.

Just in case you are interested, the traditional Japanese hand-operated blacksmith’s bellows is a rectangular wooden box with a horizontal wooden rod penetrating one end attached to a flat wooden piston inside the box sealed with leather or cloth gaskets as shown in the photos below. Sometimes the box is lined with glass for smoother operation and a better air seal. The blacksmith, usually sitting on a cushion on the floor of his smithy, or on a stool in a pit near the forge, operates this contraption with his left hand or left foot (yes foot) while manipulating hot metal with hammers and tongs with his other hand(s). Several of our blacksmiths still have these old bellows gathering dust in their workshops, but none use them anymore.

Forging & Laminating

Quality Japanese woodworking chisels are hand-forged and of laminated construction.

On the other hand, low to medium-quality hardware store-grade chisels, which have replaced all but a very few of the quality chisels made in Japan nowadays, and comprise all the chisels produced for the export market, are not hand-forged by trained and experienced master blacksmith but are mass-produced by factory workers in cookie-cutter fashion with dies and presses using a lower-grade pre-laminated steel (aka “rikizai” or “fukugozai”) produced by steel mills, a commercial product originally developed for stamping out supermarket-grade kitchen knifes by the thousands. The steel used is Blue Label steel at best, but ordinarily a cheaper equivalent material such as common SK is used. This mass-production technique typically involves only a single “heat,” and is over in just two, at most three, stamps of large presses. BTW, you may want to consider this fact next time you pay hundreds of dollars for a mass-produced Japanese kitchen knife.

The resulting products look good in their colorfully printed plastic and cardboard containers, are inexpensive to make, and quite profitable, but the crystalline structure of their steel, an essential physical detail invisible to the naked eye, and one that determines a tool’s cutting and sharpening performance, is greatly inferior to the results the more traditional, labor-intensive techniques and highest-quality materials our blacksmiths employ routinely yield.

In the traditional method, the blacksmith heats, cuts, and shapes strips of iron and steel into the necessary components using the heat of his forge, an anvil, various tongs, chisels and shears.

He then forge-welds a slip of high-carbon steel to the low/ no carbon iron strip which will become the body of the chisel using his forge, an electric motor- powered spring hammer (or hydraulic hammer in one case), his anvil, tongs and hand hammers as shown in the photos below. No presses.

Heating the iron strip (gokunanatestu) which will form the body of a chisel
Placing the high-carbon piece of steel on the iron strip for forge-laminating

With the lamination work done, he then uses these same tools combined with a few open-faced hand-dies to shape the chisel.

This process of forge-welding and shaping involves at least three “heats” (heating and cooling cycles) combined with hundreds of hammer blows. The purpose of all this dramatic fire, violence and unholy racket is to not only (i) shape the chisel blade, but to also (ii) reduce the size of the carbide crystals in the steel and (iii) distribute them evenly, preparing the crystalline structure of the steel so important to quality cutting tools and indeed modern civilization.

Modern mass-produced and low-quality chisels do not go through this process to the same degree and their crystalline structure suffers in comparison, a difference visually indiscernible without the aid of a scanning electron microscope, but one that craftsmen and warriors have highly valued since steel replaced stone, copper and iron in their tools, a difference once considered supernatural.

Annealing/Normalizing the Blade

The blacksmith will then anneal the blade 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. He will then place the blade overnight in a partially sealed container filled with rice-straw ashes, a high-carbon/low oxygen atmosphere which will relax the steel making it dead soft and more uniform, chemically speaking. While not sexy, this step is critical to making a high-quality blade, and while quite ancient, is absolutely scientific.

The blacksmith will then refine the shape of the blade using hammers and electric grinders.

Quenching the Blade

Quenching is the magic at the heart of The Mystery of Steel. This process begins with the blacksmith applying his own special “medicine” to the blade, an unappetizing and gloppy brew made from various secret materials, usually including sharpening stone mud, clay, rice straw ashes, steel filings, unicorn eyelashes & etc., that serves to control differential cooling.

When this medicine is thoroughly dry and everything is just right, he will heat the blade in a gas/charcoal fire to 800˚C (1470˚F) for a very specific time period , after which he will plunge it into water “quenching” and quickly cooling it. He may repeat this step one or two more times.

This sudden cooling creates drastic changes in the organization of the iron and carbon molecules in the steel portion of the blade. On the other hand, the iron “jigane” body of the blade lacks the essential carbon ingredient and so does not change significantly.

Extremely hard particles called “carbides” are instantaneously created during this process. These become locked into a particular crystalline structure in the steel with a greater volume than before quenching. That’s right, the steel swells.

As you would expect, this produces high differential stresses in the blade causing the steel to warp, movement the blacksmith must compensate for when shaping the blade before quenching, and while less sexy and more vexing, sometimes by corrective measures after quenching.

Naturally, the chemical nature of the steel selected combined with the blacksmith’s mastery of his craft, and of course the whims of the Gods of Handsaws, greatly influence the resulting warpage, demanding great skill and some luck if disastrous failures and expensive wastage are to be minimized.

A Japanese swordsmith quenching a long sword in the photo above. Before quenching the blade is straight, but it will warp during this step. This warpage often becomes an intentional design feature in many swords including the one shown in this photo. Please note that the “grain” pattern visible between the white hamon and “hi” groove is not a defect in the steel, but a highly-prized design feature in this art form.

Tempering the Blade

After quenching, the high-carbon steel portion of the blade is excessively hard and brittle, too brittle for practical use in fact, so the blacksmith will next “temper” the blade by reheating it to 300 °C (570˚F) ~ 400˚C (750˚F), a temperature lower than that used for forging, for a very specific time period. His precise control of time and temperature in this process will make the difference between a fine blade and a lump of expensive scrap.

Tempering reduces the amount of hard carbides in the steel, producing a less-rigid crystalline matrix, reducing hardness, and most importantly, increasing toughness.

Every blacksmith has his own techniques, but his selection of steel and his skill in using it are critical. Some steels are easier to forge and heat treat than others producing fewer failures and rejects greatly impacting productivity.

At this point in the process either the blacksmith, his apprentice, or a subcontractor will grind and sand the blade to final shape and finish. He will also grind and finish the hollow “uratsuki” to form the “ura.”

Finishing the Blade

The next few steps are where things can go crazy if the blacksmith decides to refine the shape and finish of the tool by investing extra time, effort and tools such as fine-grit grinders and sanders, and hand files, for it takes a careful eye, a sense of line and proportion, a steady hand, and many hours to achieve the perfect surfaces found in the best chisels as represented by the products of the Yamazaki brothers under the “Ichihiro” (or “Hidari no Ichihiro,” or “Tsuki Ichihiro”) brand.

The chisel in the photo at the top of this page shows the blade of a beautifully shaped and finished large fishtail shinogi ootsukinomi by Nora.

Indeed, this extra cosmetic work, which does not influence performance in any way, will increase the cost of producing a single chisel of the same performance 5~10 times. Would Beloved Customer be willing to expend that much additional money for improved cosmetic appearance in a working tool? Your humble servant has scratched that sculptural itch many times (too many times, says She Who Must Be Obeyed), but most craftsmen are not willing to lay out the additional hard cashy money.

Mr. Yamazaki

In fact, many Japanese craftsmen, even those who have a fetish for beautiful tools and are willing to pay the necessary funds to procure them, will usually leave such tools safely at home or in the workshop to save them from Darwinian adventures, and take a less valuable set of chisels to the jobsite instead, another layer of expense. Ah, the sacrifices we make for art! (ツ)

A 42mm Oiirenomi by Hidari no Ichihiro, the Yamazaki Brothers (RIP). Far from new, but beautifully shaped and finished, none better in all Japan.
A kotenomi in the Chiyozuru Korehide style by Kiyotada. A serious cutter that has seen lots of use, it’s beautifully shaped, but the filework is not quite as nice as the Yamazaki brother’s work, IMHO.

The Sharpener

At this point, the blacksmith’s job is done and the blade is handed off to a sharpener. Please note that some blacksmiths, including Mr. Nakano, our master plane blade blacksmith, prefer to sharpen their blades themselves, and for good reason.

Sharpeners typically do piecework and so strive to do as many chisels as they can as quickly as they can. The problem we face lately is that the number of skilled sharpeners in Japan has drastically decreased leaving us few choices. Sometimes the quality of the sharpening job is less than perfect, something that is also reflected in the low cost and less-than-perfect precision of the ura lands. We think it’s a fair trade. Please note that these are all conscious decisions agreed to in face-to-face discussions with the craftsmen, not default specifications.

Mr. Takagi (adze smith & sharpener RIP) at his sharpening stones

The Handle Maker

Mr. Hasegawa, handlemaker, in his workshop

The sharpened chisel blade next goes to a handle maker. He has an important job because the handle is the interface between Beloved Customer and the tool, and through which tons and tons of impact forces are transferred to the cutting edge.

Mass-produced chisel handles often have poor tolerances that don’t accommodate the steel hoop and ferrule well, or that don’t transfer the hammer’s energy properly producing tiring harmonic vibrations in the tool. We don’t use inexpensive, mass-produced handles but have Mr. Hasegawa custom make them himself from select wood to match our blades and the selected metal furniture. Even then, it is wise for each end-user to setup their chisels themselves for a more perfect fit.

To conclude the discussion about production methods, it is important to understand that our tools are produced more in keeping with traditional methodologies and division of labor by specialist craftsmen, rather than automated mass-production methods using unskilled factory workers, cheap materials, and higgledy-piggledy techniques.

The Chisel Owner’s Role

Why is all the stuff discussed above relevant, you ask? Good question. It matters because until recently in Japan, and in even Europe, a craftsman would commission a chisel blade directly from a blacksmith who would provide a shaped, ground and filed but unsharpened piece of metal with a squared-off end cut at more-or-less 90˚.

It was the end-user’s responsibility to grind and sharpen the blade’s blunt cutting edge himself. Ergo no sharpener.

He would purchase the iron furniture (hoop or katsura and kuchigane or ferrule) from another specialist blacksmith shop, and make his own handle with his own tools from his own wood. Ergo no handle maker.

It’s only been recently with the rise of large cities and cheap distribution networks made possible by rail and roads that finished products have become commonly available as retail products.

Please remember that, despite what the movies present, for many thousands of years prior to the Meiji period and the Westernization of Japan, it was a not a single, united country, but a collection of desperately poor medieval fiefs ruled by ruthless despots in which hundreds of thousands of common people, including woodworkers, died every year due to internal wars, illness and mass starvation. Craftsmen too were poor and had little disposable funds.

My point is that self-respecting craftsmen worldwide disdained paying others to either sharpen their blades or make components for their tools that they could make themself. The remnant of this historical fact seen nowadays is that the experienced craftsman in Japan does not expect a perfect tool, but expects to perfect his tools himself to his own taste.

Let us next get to the heart of the subject and consider the typical challenges one must deal with in the case of hand-forged chisels, beginning with the most common one.

Challenge No. 1: The Ura Is Not Planar

Ideally, the polished lands surrounding the four sides of the hollow-ground uratsuki are all perfectly planar, but as the erstwhile cutter quoted at the top of this article said, “Perfection is Impossible.” And your humble servant would add that it ain’t even necessary.

Despite this obvious truth, some inexperienced Gentle Readers expect the lands of the ura surrounding the hollow-ground “uratsuki,” the area at what is called the “flat” in the case of Western chisels, to be perfectly planar, even though Western chisels seldom have perfectly planar “flats,” but only what look like flat surfaces. Your humble servant agrees that perfection is nice, but it is not a reasonable expectation in the case of medium-priced professional-grade tools.

Gentle Readers who expect the appearance of CNC precision in their tools should either stick with the sharpened screwdrivers China produces in such abundance and which are sold in the West as “chisels,” or plan on spending 5~10 times the cost of mass-produced chisels, assuming you are able to find anyone that makes such quality nowadays.

In any case, an ura that is not perfectly planar is not a defect. The article at this link can help you understand how to deal with ura problems in an efficient and professional manner.

Challenge No. 2 – The Blade Chips

Our blades are intentionally made harder than most Japanese chisels produced nowadays because hardness is essential in a professional-grade chisel. As explained at great length in the article linked to above about “Professional-grade Chisels,” on condition the crystalline structure of the steel is what it should be, a hard blade will usually become sharper, will cut more wood, and will stay sharper longer than a relatively softer blade thereby reducing the frequency of sharpening, consequently increasing the professional’s productivity. This is an essential performance criteria in a professional-grade chisel.

But hardness is not all blue bunnies and fairy farts because a harder blade is less tough than a softer blade and can be damaged if abused. Warranty claims from amateurs and fools who use their chisels as if they are screwdrivers or scrapers instead of finely-made cutting instruments and then blame the blacksmith for the damage their ham-handed abuse wreaks are exactly why nearly all Japanese chisels produced nowadays are intentionally made softer and less efficient. Most are still harder than Western chisels, make no mistake, but they are too soft for professional use.

Beloved Customer should adopt the four solutions described below so as to not abuse your chisels thereby preventing chipping and keeping your eager blades cutting as long as possible.

Solution 1 – Maintain a Proper Bevel Angle: Pay attention to maintain a proper bevel angle, one that will adequately support the extreme cutting edge against chipping. 27.5~30˚ is standard. Procure a bevel angle gauge, use it frequently and correctly, and pay attention because the construction of Japanese chisels is conducive to the bevel angle gradually decreasing over many sharpening sessions. Please read about Supernatural Bevel Angles for more details. Silver crosses and garlic necklaces are optional.

Solution 2 – Cease and Desist Tool Abuse: Your chisel is a highly-refined tool specialized for cutting wood and must not be to be used for anything else. Period. Don’t use the cutting edge of your chisel to open paint cans, turn screws, scrape gaskets, or even pry wood chips out of mortise holes because such abuse will place forces on the cutting edge in directions it is not designed to handle dulling the blade quickly, and maybe even causing it to chip. Seriously.

Solution 3: Shun The Chisel Wiggle: Don’t make your tools perform the lewd “chisel wiggle” when cutting mortises, for such unseemly gyrations will damage their cutting edge. Just don’t do it. For a more detailed explanation, please see the article at this link.

Solution 4: Cut Only Clean Wood: Don’t use your precious chisels, planes or saws to cut nails, screws, concrete, rocks, sand or dirt. What? None of the wood you use is infested with such evil substances? How do you know unless you check? Please see the article linked to here to better understand The Mystery of the Scratched Blade.

Challenge 3 – Blades are Difficult to Sharpen

As mentioned above, the blades of our chisels are especially hard by design to become sharper and stay sharper longer than standard chisels thereby improving the craftsman’s productivity. But given the same area of steel, measured in square inches or square millimeters, harder steel takes more time and/or abrasive effort to sharpen, as I’m sure you’ll agree. So how can one sharpen this harder steel efficiently?

Solution 1 – Use Diamonds: Use quality diamond stones/plates instead of regular stones (although regular stones are almost as quick if used properly and a lot cheaper).

Solution 2 – Use Skill: Learn how to sharpen your chisels in a professional manner. We have a series of 30 articles beginning at this LINK about sharpening Japanese blades that may prove helpful.

Solution 3 – Reduce the Frequency of Sharpening: There seems to be two or three mindsets about sharpening in the world. One is what I call the Teutonic Solution, which is to make the chisel’s blade soft and easy to sharpen. This also makes the chisel tougher and less likely to chip, but on the other hand it means the blade will never cut very well and it will dull quickly. For those who don’t need sharp blades and lack sharpening skills, this is a good solution, I suppose, but the poor-quality work such blades can accomplish, the excessive time and sharpening stone they waste, and their decreased useful lifespan is unacceptable to professional Japanese woodworkers.

The other mindset I call the British Solution, which means a medium-hard blade; A compromise yielding more efficient, but nonetheless compromised results.

The third mindset is the Japanese one, which is to make the blade as hard as practical. It was once the same mindset in Europe and America too, but no longer. Please see the article at this link for details.

This solution is to use your blades in accordance with the principles detailed in Challenge 2 above, and maintain them properly thereby reducing the frequency of sharpening.

Solution 4 – Reduce the Amount of Sharpening: The essence of this solution is to sharpen your blades efficiently, so that less metal must be abraded/polished and turned to mud during each sharpening session. For this solution to be effective Beloved Customer must develop an essential skill, namely to learn to sense when your tool has dulled to the point where it is best to stop work and resharpen the blade while the blade can still be quickly and efficiently resharpened thereby saving time, steel and stone, instead of banging away with the chisel until the edge deteriorates to the degree it will take major effort and excessive time on rough stones to resharpen. This is a vague skill that takes time to obtain and self-control to implement, but it is an important one worth developing.

Challenge 4 – Handle Setup is a Pain in the Assets

Your humble servant has performed setup procedures on hundreds of chisels, and while it can be pleasantly meditative at times, indeed the perfect opportunity to bond with a new tool, I acknowledge it’s sometimes a burden. We recommend Beloved Customers setup the chisels they purchase from us in accordance with the instructions in the article at this link. Why? Because it will help the chisel’s handle last longer and sometimes will make the chisel perform better. That said, while not doing all the setup steps described in the article will not make your chisel self-destruct, it may cause you to inadvertently damage its handle over years of hard use.

Solution – Setup Only The Hoop: If you can only do one step in the setup procedures for your chisels, chamfering and fitting the hoop is the most important. All else can wait if it must.

Setting up the katsura hoop is the single critical task in chisel setup. Failure to do so can lead to the damage seen in these photos over years of service, especially if a hammer with a domed face is employed.

Challenge 5 – The Mystery of the Disappearing Itoura

As mentioned above, the itoura is the land at the ura located immediately adjacent the cutting edge. In fact, it forms one-half of the cutting edge. Sharpening the blade’s cutting edge makes the blade gradually shorter and the itoura gradually narrower, eventually making it disappear entirely, unless proper technique is employed. Please note, however, that a narrow itoura is not a bad thing up to the instant it ceases to exist. So, how best to deal with the Mystery of the Disappearing Itoura?

Solution 1 – Balance the Abrasion of the Itoura and Other 3 Lands of the Ura: Besides making the blade sharper, abrading the ura uniformly during sharpening produces the following two consequences: (1) All four of the lands surrounding the uratsuki (hollow-ground depression at the ura), including the itoura, gradually become wider, each to varying degrees; and (2) The uratsuki gradually becomes shallower. The solution your humble servant presents here is to pay attention to the itoura’s width, and to abrade the ura at a pace and in a focused manner that maintains a useful itoura even as the blade becomes shorter, but without excessively wearing out the uratsuki. A balancing act of sorts.

To do this, besides having an attentive eyeball, and while it may seem counterintuitive, you must not focus abrasion evenly over all four lands of the ura, but instead focus finger pressure and therefore abrasion primarily at the itoura instead, while at the same time keeping the 4 lands at the ura more-or-less planar. This is counterintuitive to people accustomed to the uninterrupted slab of apparently flat steel on Western chisels, but it requires the sharpener to apply focused, fingertip, point control instead of just chugging a beer, plopping the blade’s ura on the stones, leaning in and grinding away like a badger digging a yummy gopher out of its hole. This hand/eye skill is one the woodworking gurus selling books and classes either don’t know or overlook, shame on them, and the goobers on LubeTube will never even consider.

Solution 2 – Restore the Itoura Through Uradashi and Uraoshi: The Mystery of the Disappearing Itoura is typically more of a problem for plane blades than chisels, but the same techniques used for plane blades can be used to restore the itoura of a chisel through a couple of processes called “Uradashi” and “Uraoshi” described in great detail at the article linked to here. However, please note that, while these techniques work well on plane blades and carving chisels, they do not work as well (or at all) on narrow chisels due to the extra-rigid construction of their blades. Consider yourself duly warned.

The beautiful ura of a new Hidari no Ichihiro chisel. Please note that it’s too narrow for uradashi to work if the itoura evaporates some day.

Challenge 6 – The Uratsuki Dissapears

As mentioned in Challenge 5 above, sharpening the ura’s 4 lands abrades them making them wider, and at the same time, the hollow-ground uratsuki they surround, shallower. Appearance aside, a shallow uratsuki is no big deal except that the resulting wider lands take more time and stone to polish with each sharpening session, a problem because time is money and good stones ain’t free.

Solution 1 – Employ Balanced Sharpening: This solution is similar to Solution 1 in Challenge 5 above, but somewhat the inverse. As described in our series of articles about sharpening Japanese tools, unless there has been major damage done to the cutting edge, such as a chip or busted corner, it is seldom necessary to use anything but your finest grit sharpening stone to polish the ura. What typically causes the uratsuki to mysteriously disappear, however, is a craftsman using only a single grit of stone, usually a rougher one like 800 or 1000 grit, to frequently sharpen both bevel and ura in the interest of saving time. Don’t get me wrong: this is a valid sharpening strategy, one frequently employed by professionals under pressure, but hard on chisels and wasteful long-term. Even if you are in a hurry, the time spent working the ura on a finer 6,000 grit stone instead of quicker-acting rough stones is a good investment in your chisel, IMHO. But on the other hand, time is money….

Solution 2 – Accept the Dictates of Fate: No one is getting younger except me and thee, but chisels have a useful lifespan, usually defined as the quantity of sharpening sessions it endures rather than simple time. When, after many sharpenings, the uratsuki of Beloved Customer’s chisel bottoms-out despite your best efforts to preserve it, I recommend you smile at it warmly when you are alone together, call it a good and faithful servant, and keep using it until nothing is left but the handle and the neck, for even then, it will be a better friend than any chisel-shaped Chinese screwdriver, even if the label says “Made in Germany.”

YMHOS

The diminished ura of a still-useful oiirenomi chisel. A good and faithful servant indeed.

A few relevant articles can be found at the following links:

The Story of a Few Steels

The Ancient Art of Hand Forging

Sharpening Part 6 – The Mystery of Steel

Sharpening Part 7 – The Alchemy of Hard Steel

Sharpening Part 8 – Soft Iron

Sharpening Part 9 – Hard Steel & Soft Iron

Sharpening Part 10 – The Ura

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 to find our products 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 or fascist facebook and so won’t sell, share, or profitably “misplace” your information. May all my ura perpetually overflow with effluent if I lie.

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New Ootsukinomi Paring Chisels

Envy was once considered to be one of the seven deadly sins before it became one of the most admired virtues under its new name, ‘social justice’.

Thomas Sowell

We’ve recently received a long-awaited (and we feared long-forgotten) order of two-handed Ootsukinomi paring chisels from our blacksmith. This post is a simple show and tell.

Your humble servant has scribbled about this tool in this article in our series about the varieties of Japanese chisels

Ootsukino, pronounced oh/tsuki/noh/mee, are large, long-handled paring chisels, the equivalent to the “slick” in the US woodworking tradition, a standard tool for timber framing. It is a rare chisel nowadays, and difficult to make.

This chisel is never struck with a hammer, but is pushed two-handed to pare surfaces and joints in wood to final dimensions. The long handle provides much greater angular control and precision than a standard paring chisel, while the ability to grasp it firmly in two hands makes it possible to effectively employ the greater power of one’s back and legs.

We also carry Mr. Usui’s Sukemaru-brand ootsukinomi, but after looking for a less-expensive option for our Beloved Customers, we ordered these from our Nagamitsu blacksmith over five years ago. Soon after placing the order we despaired of them ever being completed due to the difficulty of forging and shaping them in his advanced years, and did not want to pressure him. But we were surprised to learn recently, indeed after he had retired, that he had actually made significant progress on nine 2-piece sets, lacking only sharpening and handles, and so arranged for them to be completed. At long last they have been delivered.

Yes, this variety of chisel can be procured individually, and Mr. Usui of Sukemaru fame has been kind enough to fill many special orders to meet specific requirements of our Beloved Customer. But the standard way to purchase these in Japan is a 2-piece set, one chisel in 42~54mm blade width and the other in 24mm. We had these forged in the most common 48mm and 24mm boxed sets.

The overall length of both chisels is approximately 640mm (25-13/16″) with a 140mm (5-1/2″) long blade, 160mm (6 -19/64″) neck, and a 340mm (13-25/64″) handle made of an attractive grade of dark-red Japanese red oak. Both chisels have a standard, nicely-formed single ura with the hardened steel lamination properly wrapped up the blade’s sides for the extra toughness and rigidity essential to this tool.

A triple-ura on the 48mm chisel is a useful feature, and we have had Mr. Usui forge his chisels with this detail, but it would have added quite a bit to the cost and so is not available in this more economical brand.

The 48mm chisel is used for paring wider joint surfaces, the cheeks of tenons, and the interior side walls of mortises. It’s the standard mentori beveled-side design seen in our mentori oiirenomi, hantatakinomi and atsunomi.

The 24mm chisel is forged in the shinogi style with a more triangular cross-section to provide clearance for the blade in tight places to pare the many dovetail joints used to attach beams, purlins and bottom-plate (土台) timbers, as well as the end walls of the many 24mm mortises commonly found in traditional timber framing work.

These are not mass-produced tools but hand-forged in Japan from beginning to end by a highly-experienced blacksmith in his one-man smithy using Hitachi Metal’s Yasugi Shirogami No.1 high-carbon steel (White Label No.1 steel), famous for its superior sharpness, ease of sharpening, and sharpness retention performance for the cutting layer, forge-laminated to a softer low-carbon steel body and neck for toughness, typical of all our Nagamitsu-brand products.

These are nicely shaped and finished, top-quality, serious chisels for serious work, but are not suited to everyone. While joiners that make large doors and panels often have a set in their workshop, most cabinetmakers and furniture makers will seldom need such large chisels. But they are one of those tools that when you need them, nothing else will do. Indeed they are indispensable for cutting precise joints in large timbers and joinery, even when those joints are hogged-out using electrical equipment.

At this reduced price, We only have a few sets looking for new masters who will feed them lots of yummy wood, so if you are interested, please contact us using the form below.

YMHOS

SONY DSC

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. If I lie may every spoonful of burgundy cherry ice cream I ever eat taste like dirty truck tires.

8 responses to “New Ootsukinomi Paring Chisels”

  1. Gary Avatar
    Gary

    Very nice, Stan. I have a couple of similarly sized ootsukinomi. Besides large joinery, I find that picking one up and waving it around is useful for chasing people out of the shop. It gets their attention.
    I have a question about sharpening these. I know that it is easier to remove the handle for sharpening the blade. But after a few rounds of this the handles have become too loose. I have added paper shims inside the mortise for the tang, but that seems a short term solution. Is there a better long term solution, or should I just continue to add shims?

    Like

    1. covingtonandsons Avatar

      Thanks for your comment, Gary! I have never waved an ootsukinomi at, or used one to chase away, people, politicians or even pixies (descending order of humanity), but it sounds like a fun time was had by all. Please send link to video! (ツ) An ootsukinomi with a loose handle is extremely irritating, and if it becomes loose enough for the blade to separate from the handle on it’s own at an importune time that pervert Murphy may have a wonderful time dancing naked in puddles of red sticky stuff (sorry, no video). So while I don’t recommend routinely removing the handle after the initial sharpening, I do recommend using a honing jig to help maintain the proper bevel angle on the stones. Most people use a large block of hardwood cut at an angle and inlet to fit the chisel’s face for stability. When the wood becomes worn and the angle skewampus it can be refreshed with a thin angle-cut on a table saw, or maybe a pass or two on a jointer. I suppose the commercially-available jigs like the Lie-Nielson widget (perhaps with jaw extensions?) would work too and last longer, but whatever method used, it requires more physical effort and concentration than a shorter chisel does. Looking forward to the video! Stan

      Like

  2. Gary Avatar
    Gary

    Thanks, Stan. I have a little sharpening widget that fits the blades but the long handle makes using it awkwardly unbalanced. I’ll go with a shop made hardwood fixture. And I’ll work on that video.

    Like

    1. covingtonandsons Avatar

      You’re right of course about how awkward and over-balanced the handle makes the process. Two options for the block. The first is moving the block/chisel on the stationary stone, and the second is to clamp the chisel/block down and move the stone over the blade’s bevel. The latter takes gear and time to setup, but perhaps yields better results with less risk. 2 drachma.

      Like

  3. Bruce MILBURN Avatar
    Bruce MILBURN

    COVINGTON & SON

    To your humble servant from another humble servant. Let’s not argue our spiritual merits! I enclose a couple of photos of a chisel I sadly only use occasionally. I’m too ignorant to identify its origins but it feels good in the hand when working or not. You might enjoy! Yours Bruce Milburn (convictions in darkness)

    Sent from my iPad

    >

    Like

  4. The Lost Scrolls of Handwork Avatar

    I’d like your opinion on this brand of Japanese waterstone, Ikeda, which has 10 000 grit. Is it all the vendor has made it out to be? I’m thinking of switching from a strop to a 10,000 grit stone . There are several reasons why I desire to change. The most accurate response is that I’ve always been interested in higher grit stones and am eager to compare them to strops.

    Like

    1. covingtonandsons Avatar

      Sorry, I don’t have experience with the Ikeda stones. I suggest you beware of hype related to stones, especially if costs are high.

      Liked by 1 person

      1. The Lost Scrolls of Handwork Avatar

        Thanks for your quick response. The costs for everything is too high, but it’s on special $150 down from 200. Basically, it’s down to what it was originally priced a year or so ago. On average, the 10k grit stone irrespective of the brand is priced around $150-200

        Liked by 1 person

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Sanity Retention Implements

This is how your humble servant often feels at the end of the day. I need my chisels, I need my planes!

To achieve great things, two things are needed: a plan and not quite enough time.

Leonard Bernstein

Does Gentle Reader ever feel tired, restless, or achy after a difficult experience? Do these symptoms ever progress to insomnia, headache, neck pain, backache, chest pain or even (heaven forfend, I need a fire extinguisher) untimely spontaneous human combustion? And do any of these symptoms persist even after the pressures that precipitated them are gone? If so, you may be a human, perhaps even one of those with a brain and a soul connected to your body.

In this article, your most humble and obedient servant will, as Tim the Toolman Taylor often did, dare to diverge just a step or two from the beaten path of tool talk to consider how tools and woodworking may help us mitigate the dangerous stress most modern humans experience daily. So hi ho neighbor, let’s have a conversation over the fence.

A Tale of Stupidity

I promise you nothing is as chaotic as it seems. Nothing is worth diminishing your health. Nothing is worth poisoning yourself into stress, anxiety, and fear.”

Steve Maraboli

Allow me to begin with a true story, one of stupidity and toxic stress, just another fun day at the office.

Many years ago when the world was bubbling with promise, my head was fuzzier, my beard was darker and my waist was slimmer I was employed by a mid-sized Midwest construction company doing a design/ build factory for a Japanese precision parts manufacturer. Besides the construction of the factory expansion, the work included installing foundations for carburizing ovens used to create a hard skin on the steel parts they manufactured. I was tasked with marking out a concrete slab for core-drilling a series of pier foundations to support these ovens.

Everything went well, my layout drawing was approved, the slab was cored and piers were cast on-time. But when the equipment supplier’s salesman came to inspect the foundations he informed my boss they were spaced incorrectly. A disaster!

BTW, I was never told why my layout was wrong, but once the ovens arrived it was as obvious as the bill on a duck’s face that the manufacturer’s drawings didn’t match. In any case, at the time I was certain the foundations would need to be reworked, delaying installation of the ovens, and consequently the Owner’s production start, so I was sick with embarrassment at probably having delayed the project, and felt obligated to repay my employer the cost of remediating my apparent mistake. So between personal shame, the fear of potential schedule delays, and the thought of paying thousands of dollars out of my own pocket to make things right I was seriously stressed for about a week. Headaches, stomach aches and chest pains ensued forthwith.

My boss was a steady guy named Jim who heard out my profound apology while squinting at me like Blondie frequently did at Tuco the Rat, then snorted and called me an “ijit.”

Jim explained that if everyone who worked on a construction project were to be held personally financially responsible for minor unintentional mistakes, no one would do anything. And even if they were held responsible for their screwups, the construction company would then be obligated to pay them for everything they did right as a percentage of the project’s profits. And that wasn’t the arrangement.

Although Jim was gruff, even insulting, the results of his impromptu jobsite trailer therapy session were undeniable, providing me with necessary perspective, quickly dissolving the emotional stress that was crushing me, even relieving the physical symptoms I was suffering. And all without a couch! We all need someone like Jim.

When the crew that came to install the carburizing ovens entirely ignored the footings we had installed, but bolted steel “I ” beams to the slab instead, and then mounted the ovens on them I was shocked, even a little angry! They explained that’s how they always installed their equipment. And yes, all my self-recrimination and stress had been silly.

No doubt many Gentle Readers have learned similar lessons, but there’s a quote I’m fond of by Winston Churchill, the Prime Minister of England during WWII, a former soldier and fearless leader who bravely persevered as bombs and missiles rained down around him, the nation’s cowardly bureaucrats and politicians hid like rats in rubbish piles, civilian women and children were being murdered, and his nation was about to be invaded by a brutal enemy, to be apropos to most (but not all) stressful situations:

When I look back on all these worries, I remember the story of the old man who said on his deathbed that he had had a lot trouble in his life, most of which had never happened.

Winston S. Churchill
An iconic photo by Yousuf Karsh of Winston Churchill taken at the Hotel Château Laurier in Ottawa, Canada. Known as The Roaring Lion, it was stolen from the hotel’s Reading Room sometime after 2019, but it still has wide circulation as the image on the Bank of England’s £5 note. The story goes that Churchill did not want to be photographed, but permitted Karsh a single shot. To make the photograph more interesting, Karsh suddenly plucked Churchill’s ever-present lit cigar from his lips just before triggering the shutter prompting the glowering visage.

Herding Cats

Since those halcyon days my philosophy towards life and work has changed.

I once vainly believed I could control the people around me, or at least those I was responsible for, but with experience came the realization that attempting to control people is like pushing cats towards a goal with a small broom while demanding they knit sweaters along the way. The truth is that I have never been in control, that I can never successfully make anyone do anything, and that whenever I try to, all semblance of goodwill and cooperation is lost as everyone scatters and stress levels skyrocket.

One can never successfully “herd” cats, but at best only “lead” them (and sometimes even people) to go where you want them to go, or to do what you want them to do, with fish in hand, an even tone of voice and frequent ear rubbing, if you know what I mean.

While I don’t push people nowadays, I frequently have Clients, mostly inexperienced, egotistical, mid-management types who don’t have a clue but are frantic to climb the corporate ladder, consequences be damned, who expect such counter-productive foolishness of me on their employer’s behalf. Without appearing to refuse or contradict, of course, I always try to find other solutions, but when this is not possible and the Client stubbornly insists on Marxist measures, I separate myself from such projects because I know they will not only fail, but will yield unpleasant consequences for everybody involved, including tons of shame and crushing stress for me.

Don’t get me wrong, construction projects involve coordinating the efforts of a lot people, and sometimes stern measures are necessary, but nowadays while I still plan, lead, encourage, monitor, track and report progress, remind, sound alarms, send warnings, chide, reward, and even contractually penalize when necessary, I don’t push.

So here’s your unworthy servant’s current philosophy about life and stress in a nutshell:

  1. Thoroughly understand your goals, objectives and responsibilities, plan how to accomplish them, be diligent in achieving them, and never blame others for your mistakes;
  2. Without exception, everyone makes mistakes, constantly, so be as kind and understanding as reasonably possible. If you’re lucky, they might just return the favor, but even if they don’t, it will help to decrease stress levels all around. They’re just cats after all;
  3. Don’t accept responsibility for anything for which you are not truly responsible;
  4. Although senior executives in both the private and public sectors frequently secure their high pay and lofty station by abusing the goodwill of others, no matter how cleverly or coercively they present it, don’t allow anyone to foist either their responsibilities, or their mistakes, off onto you (unless you agree to it in advance and they pay you oodles of money for the resulting stress);
  5. As taught by those Great Philosophers Lord Buddha of India and Red Green of Possum Lodge, always remember that life is suffering, all the time, and accept that Murphy will carnally poke you with his pointy purple pecker often and painfully, so don’t expect an easy time, and prepare Vaseline and bandages accordingly.

One last philosophical concept that I have found useful. In the West there’s the saying that goes “water off a duck’s back,” meaning “nothing bothers you.” In Japan they have a more colorful saying, one that many small boys have enacted, that goes “piss in a frog’s face.” To the duck it’s just another wet day in a wet place. To the frog, it’s just a warm shower. Since killing stress originates in the mind, the expectations of the duck and the frog are worth emulating. Seriously.

I believe that internalizing the 5 points listed above, perhaps urinating on frogs 𓆏 occasionally, and employing small remedies frequently rather than making big corrections too late, can minimize the need for Dr. Alonzo’s Pretty Purple Pills, those dreadfully unfashionable and scratchy canvas jackets with straps and buckles that chafe the crotch something fierce, and/or heart surgery.

Setting amphibian abuse, chest incisions and uncomfortable fashion aside for now, let us next consider one such small remedy.

Stress Reduction Measures

The criminal pharmaceutical companies and their well-paid “scientists” (aka “shills”) in the medical profession will happily sell you heaping pallets of pills to cure what ails you, but honest doctors frequently recommend less profitable, but no doubt more effective measures, including exercise, more sleep, vacations, music, reading, spending time with friends and family (even though they are frequently a cause of high stress), and hobbies. Some of these may work for you. I’ll touch on hobbies more below.

Many people like to imbibe a drop of grog at times to relieve accumulated stress. This is certainly the case here in Japan where people generally love demon rum but become inebriated easily due to a common genetic enzyme deficiency. But as someone who is frequently forced to spend time in the company of drinkers in business situations, I’ve concluded adult beverages don’t actually relieve stress but only make the drinker forget his problems for a few minutes as they worsen, turn him into a useless fool for a few hours, and destroy his liver forever. And don’t forget the injuries, traffic deaths, fights, jail time, divorce, poverty, suicides and murders cork-pulling always produces. Such an uplifting beverage.

One of the disadvantages of wine is that it makes a man mistake words for thoughts.

Samuel Johnson

A less addictive and more reliable method I have found effective for relieving the stress that originates inside my head and heart is to do selfless service for others, service that I will not be rewarded for, and ideally, service I will not receive recognition for. Are there lonely, stranded, hungry, poor, sick, handicapped or damaged people in the neighborhood? Can I help by picking up stuff for them up at the grocery store or pharmacy? Can I give them a ride to a doctor’s appointment? Are their doors, windows, locks, cabinets, furniture, water heater, car brakes or roof giving them grief? Do they need help paying a bill? Do they just need someone to talk with? To share a burden is to halve it. To carry a friend or neighbor’s burden is to lighten my own narcissistic burdens (everyone has them), at least partially. Serving others without expectation of reward or recognition is powerful medicine in so many ways.

Another method I know that works is meditation, as in spending time alone in a quiet setting, without distractions, pondering simple questions internally without seeking actual answers. No, you don’t need to be a navel-gazing monk or smelly swami to do it, but you do need privacy and quiet, conditions often difficult to secure at home, especially since, regardless of her age, the female of the human species congenitally cannot tolerate the sight of a man being content while doing nothing, and upon seeing such a pitiful fellow, cannot stop herself from insisting he get busy following her orders. Thus it has always been.

But there’s another form of meditation your humble servant has found to reliably relieve stress, performed not in a hidden Shaolin temple or in a secluded grove, but still in a private, if perhaps dusty, environment.

The Holy Workshop

A beautiful 54mm Otsukinomi Paring Chisel by Nora.

Although I once worked wood professionally, it’s only my hobby now. But I find it that, when done correctly, even meditatively, it can be highly effective at relieving stress. To do it correctly, however, a simple workshop is necessary, one without email, telephones or other distractions.

Big or small, light or dark, warm or cold, the design doesn’t matter so long as it has a door, even if it’s an imaginary one like that of the renowned radio News Director and anchorman Les Nessman (5 time winner of the coveted Buckey News Hawk Award, donchano). Once I close this door, no one but me is allowed to enter its sacred precincts or fiddle with the sanity retention implements (tools) housed therein. And that includes bench dogs and cats. But for it to be a serene, meditative, healing space, She Who Must be Obeyed and “The Spawn” must be ruthlessly conditioned to quiver at the very thought of removing my tools, and dread the consequences of chucking junk into or storing stuff in the holy workshop.

When I am in my workshop, I accept no demands to do this or do that. I don’t respond to email or the telephone, unannounced visitors ringing the doorbell, calls to dinner, much less demands to take out the garbage. It’s not that the holy workshop makes me rude and/or unresponsive, it’s simply that these distractions are lower priority than my health for a short time, and the restorative balm must be allowed to soak in, you see.

In this private space I work on my projects, usually simple woodworking or tool maintenance, using the woods I love in the company of the undemanding, sharp friends that reside, play dice and drink beer in the evenings in my toolchest. No schedules. No one to criticize or complain, no one to seek approval or payment from, and no one to please but myself. And while the fruits of my time here mostly go to others, in this bubble environment I only make what I want to make, when I want to make it, using the materials I want to use and tools that willingly link my mind and soul to the wood I am shaping.

But lo, one more thing is essential to the effectiveness of the holy workshop: When people ask me what I make in there, I always answer “wood shavings and sawdust,” for you see almost any other answer invites prying questions and ultimately stirs up invasions by curious people with too much time on their hands who will invariably request woodworking-related “favors,” responding to which will induce more stress into my ragged life. Oh, and when children ask me what I plan to give them for birthdays or Christmas, I pretend to sort through my tattered memory and then respond in a serious tone: “Do you prefer wood shavings or sawdust?”

In past years, this temple to woodworking has been a piece of old carpet laid for a few hours on a concrete slab in front of a dingy apartment for my shorty sawhorses and atedai to cavort upon. At other times, it has been a reed mat spread under quaking aspen or pine trees in a mountain glade. Most often it has been half or all of a garage with a workbench. Lately it has been a spare bedroom on the second floor of a small single-family house in Tokyo. Whatever shape it takes or amenities it may have, my workshop is for just me, my wood, and my tools.

Conclusion

Although it’s hardly worth the effort, perhaps Gentle Reader now understands the method to my madness when I call my beautiful, faithful, hand-forged tools “sanity retention implements.” I am convinced the time we spend together has, like water from a duck’s back, shed much deadly stress from my life, making my little workshop and simple handtools cheaper than therapy, tastier than Dr. Alonzo’s Pretty Purple Pills, and certainly more pleasant than heart surgery. I no longer use my tools to feed my family, but I’m convinced they “cure what ails me.” Cheap at twice the price, say I!

Let’s conclude this merry tale of mental illness with a final quote about Winston that Gentle Reader may find inspirational.

He was one of the finest orators of all time. And some of the phrases he used still resonate with us today, such as “Finest hour,” “Never surrender,’ and of course, “We shall fight them bitches.”

Philomena Cunk para-quoting Winston Churchill

YMHOS

Master carpenter Rokuza in Olde Edo with his plane and gennou hammer in hand, thinking about his lady instead of work. Some things never change.

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