1. The Master Craftsman sources the highest quality stock, checking each piece for defects, ranging from cracking to natural blemishes. At this stage he can only perform an external examination, the internal examination comes later.
2. He prepares the wood by squaring off the sides. The resulting block (called the blank) is
now ready for working.
3. He uses a template to mark off the required dimensions on the blank.
4. The Craftsman uses a Batali (hand chisel) to make a hollow in the blank. This hollow is the
net shape of the Wooob and is used to house the steel weight. The Craftsman must hollow
out the blank before carving the external shape as the wood is difficult to secure in a vice
once the external curved surfaces have been cut.
5. Upon completing the hollowing the Craftsman checks the dimensional tolerances of
his workmanship.
6. He then performs a further inspection of the wood from the inside surfaces. Here, he ascertains the overall quality of the wood, and decides whether to proceed with the blank, or
to reject it and begin again with another piece.
7. In the next stage the Craftsman uses the Batali to carve the external surfaces of the Wooob.
8. He then uses a hand Pous (a planer) to smooth and perfect the external surfaces.
9. Using a hand file, and then No. 50 sand paper, the Craftsmen smoothes the surfaces to an
acceptable level. His work is now done as he passes on the Wooob for surface finishing.
10. An expert Polisher takes the Wooob and, using No. 80 sand paper (a finer grade),
smoothes the surfaces further.
11. He then prepares the undercoat by mixing in specific quantities a paste of French Chalk, White Shellac (a natural resin) and spirit. He applies this mixture to each surface to fill the open pores which would otherwise
remain open, absorbing atmospheric water and causing the subsequent expansion and
cracking of the wood. He leaves the coating to cure for 24 hours.
12. Using a finer grade of sand paper still, No. 120, the Polisher rubs down the surfaces.
13. He again coats the wood with a mixture of White Shellac and spirit. He uses a thin,
lint-free cloth to apply and polish the surfaces, and then leaves the Wooob to dry for 20
minutes.
14. Using the same piece of No. 120 sand paper as previous, the Polisher rubs down the
surfaces again, thereby ensuring any remaining open pores are filled in.
15. The Polisher applies another coat of the White Shellac and spirit mixture. He repeats this
step 20 times in total.
16. The Wooob is inspected again as the coatings often highlight previously unseen
blemishes. Should all quality controls be met, the product is passed and then packaged. |