Dowel Cutter – A useful tool for large-scale production
A version of this post appeared here in 2012 but here is an update as prelude to a coming post.
I’ve been using a Veritas dowel and tenon cutter to rough out arrow shafts from planks. Quite a while ago I posted about the jig I built for cutting the shafts and thought it might need some follow-up. Although I didn’t have much in the way of appropriate wood available for arrows on the day the cutter arrived, I did have one well-aged straight-grained poplar board that had been set aside to age for arrows to experiment with. The cutter, once set up, takes a piece of square stock of 7/16″ – 1/2″ and cuts it down to a 3/8″ dowel.
Looking through the feed end of the dowel cutter.
When the shaft comes out of the cutter it tends to start wobbling and the effect increases quickly. The solution is to create some sort of guide for the shaft so I came up with wooden blocks, as seen below with slightly oversized holes drilled inline with the cutter. There is a second identical block set back a few inches further to increase stability. After the first few experiments I could really tell that the stabilized shafts were much smoother than the unstabilized ones.
Shavings as they exit the cutter.
The wood can be turned by hand or a wrench or, as in this case, it can be driven by a drill motor chucked with a square socket (not pictured). The drill motor is not only faster but seems to cut smoother due to the high rate of rotation.
Before and after a light sanding. Sharpening the blade reduced this spiral of fuzziness.
The above photo is blurry but the right shaft demonstrates the rough “fuzzy” state as they come out of the the jig and the left is after a few minutes with some 100 and 220 grit sandpaper. They are subsequently burnished and await nock reinforcements as the next step. After putting a better edge on the blade, the shafts come out a littler smoother but it really seem to vary with the type of wood being used.
Image from the English War Bow Society. Click the image to link to their site and find out more about English warbows.
I was able to turn out eight experimental shafts in a short time. Two were rejected immediately as they has little kinks in the grain and two were rejected during sanding due to blemishes in the wood. They’ll probably be okay for light weight kid’s bows but are not acceptable for heavy, fast bows. The spine feels a little light to me but I’ll hold out to see what comes of them. The goal is to create some fairly standard issue British war bow arrows and see how they perform. Since I use wooden dowels to peg together many other projects, very few shafts have gone to waste since this purchase.
Note: many great arrows have been cut with the Veritas cutter since the original post in 2012 and I will do my best to continue documenting the work.
Several years ago I starting documenting some of the arrow-making I do. I wrote the original version of this piece in 2012 but as it always draws a lot of interest I have re-edited it and am posting it again.
Arrows have been much on my mind after seeing how ratty some of mine have become. Even though shooting takes its toll on the fletchings, it seems they get at least as much damage in storing and travel.
I was intending to start with a set of British longbow style arrows but having received some beautiful arrow bamboo (Pseudosasajaponica) from a friend who grows the stuff, I changed plans to suit the new material. Prior to this project I had never used real arrow bamboo but have used it’s distant cousin the american bamboo or rivercane (Arundinariagigantea). It could not be much more perfect for the job.
Since I hoped to do this right, I decided to photo document the process as best I could. Good arrow making isn’t easy or fast so unless you are dedicated to perfection, you are probably better off buying them.
Matching shafts.
High-grading the materials
The first thing to do is to select shafts. I didn’t have hundreds to choose from but these were pre-selected for diameter (hence spine), straightness, node alignment, etc. so this made my work easy. I parsed out a half-dozen I liked for starters and cut them to length. Note similarity in diameter and node alignment. The scale above the shafts is in inches. I could hardly ask for better.
A preview of shafts selected, straightened, and cut to length.
Attributes to look for in bamboo or cane shafts
Your arrows should be a consistent diameter, consistent weight, similar spine, long lengths between nodes, similar node placement, with very little taper overall. Most people seem to think that bamboo is straight coming right out of the ground but this is rarely the case. Expect to heat straighten and you shafts. Your best work will be done in groups to get a consistent set, not just a one-off product.
After a lot of reading, I decided to approximate Korean style arrows with inserted wood nocks. These have worked well for me in the past but I have never started with this great of bamboo.
Remove the flares at the node sections.
Cleaning up the shafts
Raw bamboo has a flair at each leaf node that must be removed for a smooth arrow shaft. I do most of this with a knife but a small plane or file will suffice. You don’t want something bumping over the hand or bow as the arrows is loosed.
Smoothed node.
The node above is cut smooth.
Further smoothing.
I have a neat little shaft plane (made by Dick Baugh) that helps at this stage but a rasp or sandpaper will work too. You might have a divot at the joint but this won’t really affect your arrow.
Nodes are smooth.
The nodes of the set are now relatively smooth. Now, any final straightening should be done over gentle heat. This can take several hours so don’t rush it. Keep fixing little bends and make sure to heat the entire shaft to temper it. I stand over the stove for this but have used coals from the fire in a pot to achieve the same purpose. Wear gloves and be patient.
Whittling nock inserts.
I selected Osage orange for the nocks. Horn or other hardwoods can be used here as well. The above photo shows a blank and finished nock preform.
More whittling.
This photo shows the basic method. With a very sharp knife, score a ring around the nock. Whittle away from the score to narrow the piece slowly. Repeat until it fits the shafts. At this point I will say that I omitted a photo of an optional, but I think important, step. That is, to wrap the end of each shaft with sinew and hide glue to prevent the shaft from splitting while pressing in the wood. If, for some reason, sinew isn’t available, silk thread can be used in its place but you should top the silk with a little thinned white glue to help prevent it unraveling through abrasion. As sinew is free and carried around inside all the higher life forms, it should be pretty easy to get some.
Almost a tight fit.
As you get close, keep test fitting the nocks until they are a perfect fit.
A perfect fit.
You can see the sinewed shaft ends being fit with the inserts. Glue the nocks in place with a water-soluble wood glue for easier repair.
Steps in forming the notch.
At this point, several simple steps create a nice notch. First, wrap the joint with more sinew and coat in a thin layer of hide glue. Second, drill a small hole through the nock, preferably at 45 degrees across the grain. Make a small saw incision to start the carving and remove the waste with a small knife. Use a very small file or sandpaper to open the notch and smooth the surfaces.
The finished product.
At this point, you have the essence of an arrow.
Foreshafts, points, and fletchings
The next step to make these fancy sticks into arrows is to fletch them with feathers. To make fletchings, the best feathers must be selected. I am using some goose wing feathers given to me by a friend which have been graded to the last three per wing. Perhaps common knowledge in the fletching world but it worth noting that all three feathers must be from the same side of the bird (i.e., all right wing or all left wing). I cut a template from Bristol board to serve as a guide so that all the fletchings are the same size and shape. After the quills are split and trimmed, the bases (where they will be glued to the shaft) must be trimmed smooth and sanded flat to lie against the arrow. This is a very time-consuming task but critical in proper fletching.
Feathers to fletchings.
Again, there are only about three feathers on each wing suitable for fletchings and all three on an arrow need to come from the same wing to have the same shape and twist. To produce the needed 18 fletchings I cut about 24 as some may go to waste. I always ruin a few in the final trimming or end up weeding them out due to defects. Save them for later repairs if you have any left over.
Serving the feathers with silk.
After gluing them in place by hand, the ends are served with two layers of fine silk. This is a slow and tedious job and neatness really shows but the end product will be sturdy and handle a lot of abuse through shooting.
Silk in the sunlight.
The arrow above is now fletched, reinforced, and has a sturdy wooden nock. Real silk is strong and shimmers beautifully in the light and comes in virtually any color.
Inserted wood nock and goose fletching.
It takes me nearly an hour for each arrow so I took a break after the first four.
Footings
The foot is the front portion of the arrow that reinforces the shaft and connects to the point or head. This was done exactly as the nocks above but instead of drilling and cutting a slit, they are tapered to match the heads they are to be attached to.
Bodkin, foot, and sinew reinforcement.
As for points, I chose some traditional bodkins since they are good looking and very efficient. Many cultures came up with this essential design. These are English copies and are known to punch through heavy armor. They are surprisingly sharp and tear through most targets easily.
Bodkins test fitted. The joint at the wooden “foot” is reinforced with sinew.
For the photo, I dropped these from about six inches above and they all stuck in the oak. I should mention that these points haven’t had the final fitting yet and are just stuck on by friction. If you look closely in this photo, the ferrules don’t quite fit the foreshafts yet.
First four finished.
Arrows are difficult to photograph so I took this high oblique shot to show them as nearly done. I hope these images help a fledgling fletcher somewhere as it isn’t an easy task. Be patient, don’t lose hope, and be consistent. Good things take time and it really shows in their performance and longevity.
A bit of red ochre paint completes the set.
I marked my shafts with a little ochre paint made with a base of boiled linseed oil with a drop of turpentine and ground pigment. I love the natural look of ochre and enjoy knowing I found and ground the pigment myself.
These remarkably fast and true arrows suit my bow very well. A little luck, experience, and patience pay off big rewards in the end.
Every woman, high or low, ought to know how to make bread. If she do not, she is unworthy of trust and confidence; and, indeed, a mere burden upon the community. –William Cobbett
Today this should probably read “Every homemaker” instead of “Every woman” but, as Cobbett composed this treatise in 1821, he assumed that the home and cooking were the domain of the women and the men were to labor outside the home.
Bread
I have a mixed relationship with bread. I love to make it and eat it, and have for many years, yet I don’t eat a lot of it as it seems to easily fatten me up and doesn’t always sit well in my gut; the same reasons I rarely drink beer these days. However, I am very aware that bread, in one form or another, has been a staple in the Western World for millennia and should not be overlooked so I occasionally dive in and start making bread regularly again. I can’t stand the modern garbage marketed as “bread” as it barely resembles the greatness of a real, leavened or fermented loaf.
By the early 19th century, big business was already encouraging families to buy bread instead of bake at home and there can be some sense in this, especially in the city (fuel cost for cooking, the efficiency of oven sharing, etc.). Cobbett thought this purchase instead of make mentality was one of the many atrocities that kept laboring families unnecessarily poor. Foolish practices that kept the poor from ever improving their lot was a major theme of his life and we can learn from this.
It’s only the beginning of August, but there is a chill in the air in the mornings that awakens the wistful thoughts of fall, and this little song, sung by old Bilbo comes to mind. It’s not just the fall of the year, but the fall of life that beckons.
I sit beside the fire and think
I sit beside the fire and think
of all that I have seen
of meadow-flowers and butterflies
in summers that have been;
Of yellow leaves and gossamer
in autumns that there were,
with morning mist and silver sun
and wind upon my hair.
I sit beside the fire and think
of how the world will be
when winter comes without a spring
that I shall ever see.
For still there are so many things
that I have never seen:
in every wood in every spring
there is a different green.
Some Thoughts on Making Arrows, an Underappreciated Art –
I have been making my own arrows from scratch for a couple decades (since 1987 to be precise) and thought I’d showcase some I have made over the past few years. I don’t generally make them to sell and I rarely hunt these days but there is something very satisfying and meditative in gathering the materials and constructing something so practical, with such fine tuning and narrow parameters in functionality. I learned many tough lessons along the way, having no actual teacher, but I gleaned all I could from the historical resources I could find. Most cultures of the world have a martial tradition of archery and each have their advantages and limitations.
A set of seven hand-turned poplar arrows in the English tradition.
The poplar arrows above were made from aged, straight-grained wood that was split along the grain then turned in a dowel cutter. The nocks are reinforced with Bois d’arc (Osage orange) wood for added strength. The heads are conical bodkins, fletchings are prime turkey wing secured with glue and silk binding.
A “primitive” set of cane arrows with hardwood foreshafts tipped with a variety of point types.
Making matched sets –
I sometimes come across beginning arrow-makers (fletchers) who only produce “one-offs” without attempting a matched set. This is fine as an experiment or as a learning tool but does not suffice for someone who plans to actually use them for precise or regular use. The minimum I make is three but I try to produce arrows in sets of six or twelve. Since the plank used for the the arrows above worked out to produce exactly seven shafts, I kept the group together.
I believe it was a writing by Arthur Young where I first learned that to have a truly great set that sometimes you had to sacrifice a few as imperfect. With all the work that goes into an arrow, it is painful to cull one out but sometimes it must be done. The weights may match, the spine may feel the same, but one may just not fly as perfectly from the bow as the rest. In the past, I have marked these and they become stump shooters of ones that you don’t mind risking on a long or difficult shot.
Finding a perfect set of rivercane shafts can involve a lot of looking, sorting, and luck. People who want to purchase these hand-crafted materials and products rarely appreciate how much work goes into just gathering the materials. A dozen matched cane shafts may come from sorting a hundred plants, then aging, curing, and straightening before the arrow can even be started.
Rivercane (Arundinaria) arrows with reinforced self nocks.
Fletchings –
To produce enough fletchings for the above, one has to acquire three feathers per arrow, matched by side (all rights or lefts) and placement on the wing of the bird (e.g., second or third wing feather). This could mean wings from seven to fifteen animals depending on how picky one is just to produce five sets of fletchings.
Antler point.
Points –
Finally, the points are considered based on the needs of the archer. Will these be for hunting large or small game, target shooting, or just all around fun shooting? I use bone, antler, stone, wood, and steel depending on the intended use of the set. Although I purchase most of the metal points I use, a lot of time can go into making matched heads from natural materials.
Tools, clockwise from lower left: large awl, sewing awl, rivercane needle case, bone toothpick, sewing needles in center.
Sewing
I do quite a bit of sewing and I feel it is an essential skill for nearly everyone. My sewing includes new buckskin trousers, cotton shirts, shoes, a few leather bags, backpacks, and repairs to clothes to name just a few projects. All this has caused me to think about sewing without manufactured goods. Over a few evenings I decided to make a better primitive sewing kit. Although I can’t say that bone could fully replace the smallest steel needles in my day-to-day sewing basket, I have been able to make some very small ones indeed from some deer legs I have lying around.
This 7 centimeter (2 3/4 inch) needle, dated to approximately 50,000+ years before present, was made and used by our long extinct Denisovan ancestors, a recently-discovered hominin species or subspecies. the material is bird bone. Photo: Siberian Times (click the image for the full article).
Needles
I’ve learned that very small holes can be made with a largish stone flake or knife if it has a sufficiently acute point, drilling from one side and joining it with a hole from the other. From a sewing perspective, the smallest hole possible will provide the strongest needle. during the finishing on the smallest needles, I had a 50% failure rate splitting out the eye. It isn’t generally a total loss since the needle can be shortened and the hole drilled again. I actually found that using the flake like a knife (as opposed to a drill bit) was the best way to start a tiny hole, scraping a small slit until a significant indent is made. As with all new skills, knowledge and experience were gained along the way.
Eyed needle from the burial at Horn Shelter, Texas (links to overview of this remarkable shelter). Click the image for and article explaining the needle context specifically.
Despite their fragility, bone needles are found far back in the archaeological record of Europe, Asia, and North America. Small, eyed needles are generally considered, in the Anthropological community, as proxy evidence for tailored clothing or, in a few cases, surgical or first aid related. Unfortunately, needles don’t often survive and, no doubt, many small and broken fragments have been lost through the screen during excavation.
Awls
Awls are essentially a small spike used to pre-punch holes in tough or thick materials. Both the awls shown here are also based on archaeological examples; the awl being a universal tool in human communities. The metacarpal “knob” on the sewing awl still needs a bit of refinement but the round handle works well for repeated stitching in buckskin. Bone (and antler) can be made surprisingly sharp and hold an edge reasonably well.
Storing the Needles
Needles are sharp and dangerous to leave lying around so the next obvious step was to make a case to hold them. This is a simple affair made from rivercane with a yucca stem stopper. The cordage strengthens the tube and prevents splitting and the whole thing was rubbed down with pine tar for preservation (hence the dark coloration of the cord).
In use on buckskin lacing project.
Finally, with a thin scrap of bone I ground out a bone toothpick to keep in the travel kit as a toothpick is always a handy thing to have in the bush.
I love these the old sheepherder camps. I’ve seen quite a few parked on ranches from Colorado to Idaho and even a few in Arizona. I know they aren’t highway capable but it seems they could provide a real housing alternative for low-income minimalists who have access to land. Far better than a housing complex or apartment for sure if you can deal with a small footprint.
Originally designed on a narrow wagon box, the builders took advantage of every square inch of space. Since weight wasn’t really an issue, many have large stoves like the one above for heating and cooking. As most of these wagons were homes for ranch workers in the western U.S., they needed to be prepared for extreme cold and windy environments. When I was building my vardo, I took a fair amount of design inspiration from these wagons, adding their vibe to the more European designs I was ingesting. My stove is small and I envy this one above; at least the cook top.
Off-the-shelf or build it yourself? It’s the details of hand-built structures that make them stand out and this chimney cap is no exception. This looks far more interesting to me than the local hardware store option.
The photos are from Ken Griswold’s Tiny House Blog. If you haven’t figured it out yet, I’ve been a fan of his site for a long time now and recommend it for anyone with an interest in Tiny Homes. Here’s a link to the full article about Lorna’s wagon.
From the ingenuity of the Roaring 20s. Pack up with your favorite Flapper and head to the wide-open spaces!
Novel Camping Trailer Opens Into Comfortable Quarters
A NOVEL camping trailer has been produced in London which is hailed with delight by lovers of the outdoors because of the comfort it provides. The trailer, compact when closed, is attached to the rear of the automobile by a device which makes it ride easily with a minimum of side sway. But when camp is made the sides of the trailer let down to increase the available space and a door at the end provides access to the interior where there is ample headroom.
Wintergatan – Music, Machines and Homemade Music Instruments from Sweden!
I have a fondness for Rube Goldberg machines and clever design. If it is something that actually makes music as well, then I’m all for it. After watching this video I felt a need to find out more so exploring I went. It was a rabbit hole I fell into and am still learning and watching this amazing work. Have a look and listen to their machine to see what I mean. It has some genius engineering, is mechanically amazing, and even sounds great too. This is the culmination of many trials and failures but is ultimately about the music.
Inspired by earlier mechanical musical instruments, especially those in the Speelklok Museum Martin and Wintergatan were determined to make this thing work. Using CAD and a CNC cutting machine, they created this beautiful human-powered machine that can be “programmed” to play many musical pieces.
I was really fascinated by the way they dealt with time signatures on a program grid (playing triplets vs. 4/4 time for example) and he explains this all very clearly in the many videos. The following video is just the tip of a very big iceberg but is a great overview of the machine and the work that went into it.
I cannot begin to describe what they have achieved so I suggest, if you have a look at their website (http://www.wintergatan.net/) and check out their videos on YouTube where they show that actual design and construction from prototypes to finished products.
Preindustrial Craftsmanship 