Wrapping Peasants, Part I: Drafting a pattern for shoes...

Where was I before my holiday travels got sucked into that polar vortex thingy we're all tired of hearing about? Oh! Right. We were making shoes. For this, we will have to backtrack a bit to October, when I was devoting time primarily to research while recovering from my mystery ailment and various ensuing nonsense...

Part One: In Which I Run Afoul of Congress

With a finished pair of lasts in hand, my next step in my shoemaking journey was to contact Francis Classe for advice. Our conversation ranged across the spectrum of tools and patterns. This inevitably led to a tussle with the US Postal Service, who waylaid my attempt to pay him for some tools, including some surprising ones: Boar bristles, which he offered to sell to me at a very reasonable price. If only I could get the check to him (Yes, a check; if you don't know by now I'm a bit of a Luddite, you haven't been paying attention.) which I finally sidestepped by at long last succumbing to the embrace of Paypal. . . God help me.

Two closing awls and a bundle of boar's bristles. I'm semi-convinced that

Francis raises wild boar in his back yard because he seems to have an 

inexhaustible supply of these bristles... 

While I was waiting for the USPS to get their appointed rounds out of their dark of night (ahem), I headed to the library to seek out a copy of "Stepping Through Time: Archaeological Footwear from Prehistoric Times until 1800" by Olaf Goubitz.  It is essentially the book on the subject. Goubitz, who died in 2007, was a Dutch archaeologist who dedicated his life to the conservation and study of historical leather artifacts, which led to books and articles like Stepping Through Time... and Purses in Pieces. His books are full of tireless scholarship and hand-drawn patterns and replications of shoes from shipwrecks archaeological digs throughout Europe.

Thanks to his tireless efforts, I am able to approach this part of my project with more confidence that I'm approaching the subject in an historically-sound manner than I have at any other time in the past 13 months.

I'll do my best not to screw it up.

Thanks to the magic of Inter-Library Loan, in short order, I found myself in possession the People's Copy of this seminal work. By which I mean that The Library of Congress was apparently the only copy available, which led to me being the guardian of this important book, as the United States government went on hiatus almost immediately after I picked it up.

Needless to say while I was the Keeper of Congress's Preeminent Pre-modern Shoemaking Text, I took copious notes and chatted a bit more with Francis before settling on a pattern and a plan.

We'll gloss over the fact that when I returned the book after my 2-week guardianship, the librarian finally opened the envelope taped to it and discovered an admonition that I was Not To Take This Book Out of the Reading Room. She and I agreed that our legislators were far too busy arguing to care about my minor flouting of congressional mandate.

Either that or I've doomed my soul to Congressional Library Hell...

Normally this would be my idea of heaven... unless the shelves were unalphabetized.

And I had to re-shelve the books... (shudder)

image source: "15 Gorgeous Photos Of the Old Cincinnati Library" via Buzzfeed

Part II: On the Drafting of Patterns

As a painter, I've always been fond of the curious and somewhat controversial pastoral paintings of Pieter Bruegel the Elder. Especially the detail on the costumes, customs, and clodhoppers. These are the feet of two bagpipe playing peasants in the painting 'Peasant Wedding' clad in some charmingly simple-looking shoes.

Detail from The Peasant Wedding c. 1566 by Pieter Bruegel the Elder, Image source: Wikipedia

As I mentioned, Bruegel's bucolic depictions of peasant life are somewhat controversial in many circles, so I try not to trust them if I cannot back them up from more conventionally reliable sources. Which is where our old friend Goubitz comes in.

Among the shoes he documented from digs in the Netherlands were these, which I re-drew from his book. Handily, he provided a schematic of the pattern pieces as well, as you can see below.

This is where we get to the pattern drafting part of our program.

Note: I am basing my drafting methods here on years of experience drafting patterns for clothing, further informed by an article contained in the book Handmade Shoes for Men by Laszlo Vass & Magda Molnar.

This is something we'll re-visit at least twice more after we're finished with the shoes, and it's an important aspect of everything we do as we clothe our renaissance working man (or woman) from toe to head. At each level of dress, we will find ourselves wrapping parts of a body in paper and imagining flat drawings from 450 years ago into three dimensions.

Which entails a lot of paper and a helper. When drafting patterns (or as I like to think of it: "Wrapping peasants") it is best to work with a friend.  Which makes it especially appropriate since it was the week of Christmas when I started laying paper over my shoe lasts and making with the Scotch Tape and sharpies.

Once I had the shoes wrapped in paper, I approximated the seam lines from Goubitz's drawing on my new three-dimensional model, guessing in places where and how I would compensate for the contours of the wooden foot, marking out how the vamp and sides come together.

Then I used a shop knife to cut along the seam lines, cutting the paper away from the last and laying them out flat to check that they approximate the pieces that Goubitz drew for his book. 

From paper to leather to shoes... simple enough, right? We can only hope.

More later,

- Scott

The Last Last Post

For the record: I'm won't spend quite this many posts for the second last. However, on advice from Francis, I did go back out to the workbench and spent some more time zeroing in on the correct form of my last. He advised that I raise the sole about a 1/4 inch, sloping from the ball of the foot to the heel. This isn't to accommodate a heel so much as to accommodate the shape of the human foot.

This was done mostly with hand tools this time: the pattern maker's rasp and as I neared my final desired measurements, a spokeshave. I will sand it to remove most of the toolmakrs before putting a finish on it and moving on to the next one.

In the meantime, we're going to shift over and visit the Joiner's shop.  Stay tuned!

~ Scott

A bit of heel lift demonstrated by putting the heel on a handy speed square.

The less-flattened sole of the shoe.

 

...and Lasts, and Lasts, and Lasts

So apparently when Francis Class told me that the problem with modern/vintage lasts is that they're not 'flat' he meant 'didn't have a heel' rather than 'as a board'. (So to speak.)

You see, it didn't quite sink in that, unlike maskmaking, when you take the last out of the shoe, you don't cut it out. So there needs to be a bit of wiggle room in the form of a toe and heel rise to allow you to slip the last out of the shoe without stretching and distorting it in the effort.

That makes perfect sense.

Thankfully, in the conversation I had with Francis last night, it turned out I'm not the first aspiring shoemaker to grab a piece of scrap pine and try to turn it into a last. He shared this link to the shoemaking blog Where Are the Elves? Adventures in Historical Shoemaking. This guy turned up an historical last to copy. It's a 'straight last' and I'm making a 'crooked last' but more on that another time.

Also, the sole is generally a bit smaller than the shadow of the shoe. So my last needed to look even less like a shoe and even more like a foot.

I can do that.

Tonight after work I grabbed my patternmaker's rasp (Hand tools FTW!) and spent some time with my last in a vise, re-shaping the sole and putting more of a narrow waist on the new last.

I might have to shape it a bit more but I didn't want to overdo it. It's easier to take off too little than to put too much back. . . or something like that.

Worshipful Company of Cordwainers Part I: Something that lasts...

Don't call them 'Cobblers'. A cordwainer is a shoemaker, a cobbler was actually forbidden by statute from working with new leather. His purview was restricted to repairing a cordwainer's work after it failed. The Worshipful Company of Cordwainers controlled all aspects of the manufacture of new shoes.

Whence came the name? For that, we go straight to the horse's mouth, as usual...

"Those who worked with the finest leather were called Cordwainers because their material came from Cordoba in Spain. They developed a soft, durable goatskin leather known as Cordwain – the very finest leather available – importation of which contributed to the growing prosperity of London. Over a period of time, those who processed the leather formed their own guilds. The shoemakers, however, retained the name of 'Cordwainer'." - From their site: http://www.cordwainers.org

Yesterday I said I knew nothing about shoemaking going in. This is true, though I've done an extensive amount of leatherworking so "nothing" might be a bit of a stretch. My favorite form of leatherworking, in fact, is making leather Commedia Del Arte masks like the one you see below. 

Much like shoe making, masks are made with the leather worked wet and formed over a carved wooden matrix. (If you are interested in maskmaking, click here for a full tutorial I wrote last year). So the first step in making either mask or shoes isn't leather, it is carving wood.

And carving wood is something I understand completely.

First things first, I had a chat via email with Francis Classe, historical cordwainer extraordinaire and all around nice guy. He's been very helpful and supportive all along, providing not only advice, but photos and links to things he'd written as well as books of historical shoe making. Francis works with modern wooden lasts that he modifies for a period shape.

I like woodworking and I have some carving tools that haven't been taken for a spin in far too long, so we're going to make our own. (This is not to be confused with the fact that I have a size twelve foot and couldn't easily find a modern last to modify. Nope! Not at all.)

Seriously though, I shake my fist as these hobbit feet on a regular basis.

Seriously, I had to get out the big sketchbook to even trace around them. I know people with larger feet than mine and I tell you now I don't want to make shoes for any of them.

The lastmakers weren't a proper guild in their own right, so I'll be going through this pretty fast and hopefully we'll get it in one. Essentially I'll be using a lifetime of carving experience to sculpt something approximating my foot. Then I'll do it again with the other foot.

Deviation(s) from Period Techniques: Near as I can tell, the standard practice for last makers in the period is much the same as now. Hardwoods (preferably beech) are cut to a rough shape using something called a 'stock knife' which aren't easily obtained in the United States. A stock knife is a large blade with a handle on one end and a hook on the other. I'll append a video at the bottom of this post of an experienced clogmaker using one.

The hook is secured to an eyebolt in the table as a fulcrum to form a 2nd class lever. I couldn't find one and don't have the werewithal to make one, also I'll be using scraps of pine since this doesn't have to survive the ages, just the one project. If I like doing this and want to do it again, I'll make another out of a hardwood. In the meantime: pine.

Because my feet are deep and wide, I glued up a some chunks of 2 x 6 I had lying around and transferred my traced outline of my foot to the wood, trying to avoid knots and grain funkiness. Or at least use the grain funkiness to my advantage.

Step two of any carving project is to remove as much waste material as possible. The fastest and cleanest way to do this would be to cut it away with a band saw, but I don't own one. So the second best chance is to cut to the line and chop away the waste with a combination of chisels and coping saws.

It's hard to do this and take pictures at the same time and The Engineer was grouting the kitchen tiles, so forgive me if these look a bit staged. It's only because my hands aren't in the shot.

Having pared away as much of the waste as possible, only resorting to the chopsaw for the bit that crosses the knot at the little toe.  Chisels tend to glance off of knots or chunk them out completely to the detriment of carving as a whole.  A real last maker would choose a clear piece of hardwood, as I said, but we're working with what we have.

Now, more cuts to make the waste as small as possible before removing it with a smaller chisel...

Working in all three dimensions means more cuts and switching through a series of chisels and working top and bottom.  According to Francis, unlike modern lasts, period lasts tended to be flat-bottomed since heels hadn't really become a Thing yet.

At this point, it's time to switch to a gouge because it's easier to create and follow curves with a gouge than it is with a bench chisel...

Most of the waste is removed, time to get to the final shaping.

This is where I encountered a very modern conundrum. Because lastmaking is ancillary to the actual project and just this one had already eaten the heart out of a day, I was faced with another few hours of paring away at the last with a succession of knives and rasps, or I could use a machine.

My conscience got the better of me. In the end, I rasped away most of it until I's achieved something close the final shape and was starting to lose the light. Then I took it into the garage and chucked a drum sander into the drill press and finished the final shaping and sanding in one.

So... speed may kill, but it does save you from wasting more time than you have to.

Next: Do you know your left from your right? Did the Elizabethans?

~ Scott

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Resources:

"Footwear of the Middle Ages" by Marc Carlson (Website) How historical shoes were made from the middle ages through the Tudors, working from primary sources and personal experience. Great site, lots of information.

"Handmade Shoes for Men" by Laszlo Vass and Magda Molnar (Book) Modern shoe making and some inaccurate history, but valuable information on measuring feet and fitting shoes.

"Stepping Through Time: Archeological Footwear from Prehistoric Times Until 1800" by Olaf Goubitz (Book) Just what it says on the tin. Francis swears by this book. I haven't acquired a copy yet, but I'm working on it.

"Chopine, Zoccolo, and Other Raised and High Heel Construction" by Francis Classe (Website) I hesitate to risk the pun, but Francis is a class act and a generous scholar of historical footwear and how it was made. Visit his site and his blog to see this done right, thoroughly, and well.