Joy of Sectors II: Revisiting "The Arte & Misterie of Coopering"

You may remember this picture of a persnickety Perkins working the angles on a coopering demonstration.

With a bit of math and the able assistance of my consulting engineer, we determined that the eight perfectly-equal staves of my Mary Rose tankard needed to have 67.5 degree bevels so that they would align to form a perfect circle of watertight, oaky goodness.

This assumed if you didn't round off your tankard/bucket/barrel or whathaveyou that you'd have an equilateral polygon. All sides (eight sides in this case) were the same and would be worked with the typically-modern obsession with precision and symmetry.

As we discussed yesterday, that wasn't quite right. Coopers make their staves whatever width their wood allows and it's not always symmetrical and there aren't always an even number of staves. This is important since they were cutting wood straight from the log and doing a lot of their shaping with an axe. (Axes are awesome and speed up woodworking considerably, but they're not really precision instruments.)

All of which throws off my equation a bit. You could still figure it out, of course, but it just got a bit harder.

Part of the problem here is that I tend to think of barrels and tankards as segments of a ring rather than pieces of pie. I've been peeling all these apples, so let's make a pie.

Not a meat pie, you goofball, an apple pie.

Much better. (The ice cream's a nice touch, but we won't be needing it today so I'll just eat it and get it out of the way...)

Like a period tankard or bucket, the average pie slicing cook isn't going to make every slice exactly the same size. The piece for the baker is big and the piece for the kids are small. Also Aunt Agnes, who always says she's on a diet, but takes twice as much ice cream as everyone else.

The nice thing about this way of imagining a coopered vessel is that you could (if everyone can hold their forks for a minute) rearrange those pieces any way that you want and you'd still have a pie the same size as you started with. The pieces would all fit together no matter how you rearranged them in the pie plate.

But with coopering, you're starting with a pile of uncut sticks and an entirely imaginary pie that you're trying to craft out of thin air and oak. So how do you do this when you don't start with a pie?

Enter the Sector.

If you remember, at its simplest form, the sector is two straight pieces of wood hinged at one end. Pretty much exactly like a pair of dividers, except made of wood.

The geometry of the sector is devilishly simple: The two legs are equal, meaning that the legs will form an isosceles triangle. If you place it at the center of your imaginary bucket (or whatever you're making), it forms an imaginary piece of pie. If you want to make a ten-inch bucket (measured across the bottom) you just mark your sector five inches from the hinge.

That's the inside diameter of your bottom.

The second mark you see there indicates the desired thickness of the walls of my imaginary bucket.

Now, no matter where the sector crosses the the outer wall of your bucket, or how far apart the the legs of the divider have to be (to accommodate your rough-cut variations in stave width) the legs form the angle that you're shooting for. 

You found your stave bevel without writing a single number on a single piece of paper.

As you can see, this is also helpful if you decide to repair or knock off an existing bucket.

But wait, there's more!

It's not just a measuring device for finding the angle of your bevel either. It's also a jig you can use to monitor your progress as you create the bevel on your staves. Hold the bevel up to the stave as you work and align it to your marks as you go. 

The angle of the sector will tell you how far you need to lean the stave over as you plane the bevel. When the stave sits snugly in the sector between the marks, you're golden.

The importance of this cannot be exaggerated for the working cooper. And this is the part that I forgot when I was doing my demonstration.

I almost wish that building that bakery at the Washington Midsummer Renaissance Faire had been the first step in this project rather than happening in the middle. I suspect that I've fallen down on most of these projects simply because I'm thinking in terms of one-off bespoke items rather than the economies of production.

The practicing cooper isn't making one bucket at a time. This isn't bespoke bucketing on Bond Street, it's mass production because a cooper (and his apprentices) gotta eat. So if they're making as many buckets at a time as they can reasonably get away with, there's no room to be fiddling about with equations and making these exacting symmetries that we've become so accustomed to post industrial revolution.

A cooper's shop is making piles and piles of rough-cut staves and assembling them into a pile of ten-inch buckets and they all have to fit together no matter which bucket they're getting shoved into.

Yesterday I asked where I should stop. I don't know that I'm going to go back and repeat every experiment and demo that got us this far, but going forward I will certainly be taking a hard look at each of these trades and asking the question that should be obvious: How did they do this fast enough to make a living at it?

Because therein lies the real secret of most of these trades.

Now go eat some pie. You've earned it.

-Scott 

Postscript

The "Aha!" moment for this didn't come from thin air. (They never do, no matter what anyone tells you.) I've been reading about sectors recently, mostly using Jim Tolpin's books and articles so I was in the right mindset when I had the good fortune to catch an episode of Roy Underhill's "The Woodwright's Shop" featuring white cooper Norm Pederson who actually demonstrated many of the things that past coopers on that show had previously waved away as "something you learned with experience."

The episode is not available online anywhere I can find it, but you can download it for $3.99 from Popular Woodworking here: https://videos.popularwoodworking.com/courses/the-woodwrights-shop-s24-ep04-norm-pederson-white-cooperage  

Or you can buy the whole season on DVD like I did. I highly recommend it if you have any interest in trying this out yourself with better results than I had on my first outing.

Further watching...

This is not that video, but it's an excellent demonstration of white cooperage filmed at an outdood event, so the sound isn't always so great.

Thoughts from the peeler: The artisan obsession and where does it end?

There is in just about every artisan, a touch of obsessive compulsion. Whether or not it's a disorder depends on how you feel about being both obsessive and compulsive at the same time with sharp implements in hand.

I don't want to make light of a genuine medical disorder. As someone who suffers the black periods of lost joy and time that is depression, far be it from me to make light of someone else's affliction.

Obsession and compulsion exist on a sliding scale, which is set by the same people who have categorized an affection for coffee as a mental disorder.

So let's ignore those folks for a bit.

For all practical purposes, it boils down to whether your obsession/compulsion is positive or destructive influence on your life.

Be ye moderate in all things except moderation.

So it is with caffeine and beer and so too it is with handicrafts.

But where is that moderate line? When do I stop? How far do I take each of these explorations of a craft? When do I tie it off and call it good? Do I keep going until I've got it perfect? Is perfect the enemy of the good?

I discovered recently when I began exploring the uses of the sector, that I was wrong in a very important way when I discussed the many ways for finding the angle at which the staves of a bucket or tankard meet.

My methodology was modern. For one thing, we started with an equation. For another, it depended heavily upon looking at the tankard as an equilateral polygon and we did some really sweet math based on that assumption.

That was an inaccurate assumption.

Even though it worked.

As I examine more coopered buckets and tankards, it because clear to me that the old coopers didn't think that way. The staves of a bucket are rarely all the same size, and no two identically-sized buckets seemed to have the same number of staves.

My math was accurate, but my method was wrong.

The period method is really cool. It's easier. And it involves a sector and some different neat math having to do with isosceles triangles and dividers.

My assumptions were wrong and even my successful result was... I don't know. Was it a failure to achieve the goal by apparently modern means?

A period item was created, but it was based on best guesses made with a modern mind. My methods of arriving at that item were modern even though I used my best period tools to achieve the result.

I know all of this because I didn't finish exploring coopering when I finished writing about it. I kept going. I kept talking to other coopers. I examined barrels and buckets in antique shops. I made a bucket. Then I made a butter churn. Then I repaired some damaged buckets and barrels and tankards back to working order.

I know I was wrong because I didn't stop.

I made an ale pail that would hold ale, but did I succeed or did I fail.

Sorry, that was Seussical. Sometimes I can't resist.

At some point do I stop going back and adding to these projects?

Or is this exploration of artisans a reflection of artisanship itself in that the learning never actually ends? And if that's so, is my quest really impossible after all? Will I ever have more than the most surface knowledge of any of these crafts if I cannot devote more than the duration of a few blog posts to each of them?

How do I know when to stop?

And if I'm honest with myself, can I stop even if I want to?

- Scott

What I've been up to and other recent projects...

So... I haven't been completely idle this past year; I just haven't been doing anything in any sort of pre-planned and extensively- researched way. Mostly, I've been keeping myself busy when my hands were too idle and my brain too active.

Here are some of the recent projects to roll across my workbench.

Inspired by an article by Chris Schwarz in Popular Woodworking, I built a modified 6-board chest for my wife out of offcuts and scraps of VG fir from the window and door manufacturer where she works. (They were fished out of a dumpster with permission. Always get permission before dumpster-diving.) It was assembled using copper boat nails (for no particular reason) and finish with red milk paint and a coat of varnish. 

She uses it to store her video games and accessories.

Since I wasn't really doing this one for the blog, there weren't many in-progress shots. I did a few oddball things with it, though, mostly for practice, including this boarded bottom which I made using the next item on my list...



Last fall, a Craigslist post netted me this box of dusty and rusty planes. Most of them were Sandusky moulding planes, which made them a real find and worth the effort (in my opinion) to sharpen and lap the irons back to usable condition.

This box...



Begat this shelf of oiled, and ready planes. And I'm only short one iron after all is said and done, which is a bit of a miracle if you've ever bought a box of moulding planes. (I have irons for the two in the back that are sitting empty, they were in progress when I shot the photo.)



I used them to tongue and groove the bottom of that chest.

I have continued to practice at the lathe, turning out piles of oddments like these threadreels, which I based loosely on some of the reels which were found on the shipwreck Mary Rose. They're fun to make and an excellent small project to practice with the tools.

And because not everything I do generates sawdust, I've also been exploring puppetry.

Why puppets? Because I'm part of the Jim Henson generation. Also because when you've had a year like I just finished, you find yourself looking for other mouths to express yourself through, be they monster or monkey or felted frog...

This is the one facet of what I've been working on that has required a significant amount of research, which began the first time I saw Grover on Sesame Street, extending across the decades to this past year when I was sitting at a table where the nearest pile of raw materials were foam and faux fur.

This is what sketching looks like when you're making puppets.

Ever wonder how the puppets from your favorite television shows were built? This isn't the place to really discuss it, but I have documented these pretty thoroughly and might need to set up a static webpage or use them for a guest post on someone else's (more appropriately themed) blog.

Anyway, this is what's under all that fur and felt you see on TV.

The above was a commissioned piece, actually. I'll have to share the videos that his owner ultimately makes with him after he takes delivery.

In the meantime, I'm warming up the workbench (Literally. The shop was 24 degrees Fahrenheit when I was out there yesterday) and getting ready to begin the next project. In the meantime, here;s some puppet video my wife shot while I was testing the build on the big grey fellow. This is Mr Grumpigus, who is having issues.

Peeling and pondering

Sometimes, you have to grab a pile of fruit and a knife and make a pie. But really, you just... just... want to peel something.

More even than wood carving, taking knife to fruit is a supremely meditative act of creative destruction.

Care is needed lest you cut yourself, of course, but even if you mangle the fruit, who cares? It's going into a pie anyway, so make with the blade, kiddo, and let your mind wander.

I've been doing a lot of peeling recently, trying to decide how best to proceed with this project.

2015 has been a tumultuous year. My book was published and I was riding high. Then my mother died suddenly and I was left feeling high and low at the same time.

Knife to peel.
Spiraling.
Lengthening.
Try to get it all in one.
Meditate.
Don't cut yourself.

So here I am at the close of the calendar, trying to decide whether I care much for calendars. It's tempting, oh-so-tempting, to think in these discreet blocks of days, months, years. It tempts you to take up the blade.

Peel away the questionable bits.
Cut around the bruises.
Save the good fruit, dispense with the bad.
It's just a pie, it doesn't have to be pretty.

To think in calendars is seductive. It makes it easier to just pretend you can bin the entire year at will or pick or choose in phases of the moon or turning of the seasons. Hell, this entire project is and always has been dependent on calendars for its framework.

In January, can you really begin again? Boot the old man to the curb and pick up the baby in the tophat?

Time is seductive but false.
You can't time a pie, it's done when it's done.
Density, moisture, relative humidity, too many factors at play.
Keep an eye on it and yank it before it burns.

I am about to pick this project back up again. For those of you who have waited patiently while I run off to be an author and have family tragedies, I thank you for your time. I hope you don't feel I've wasted it.

Going forward, we're going to take a more meditative approach and we're going to ignore the calendar. I was wrong about the artificial frameworks for this. I was wrong to think I could just peel it and pop it in the oven and set a timer and it would be done when it dings.

We're going to carve around the worst bits and bruises and try to use the best of the fruit. And we're going to watch the food and let the pie tell us when it's done and time to move on to another pile, another peeler.

Our knives will be sharp and our pies will sometimes be ugly.

I hope you'll join us.

In the meantime, have a happy Christmas or a happy whatever celebration brings you together with your kith and kin this winter's turn. Draw near to those you love and remember those who are missing. Share food and companionship and warmth and remember that they are the only real light that matters in the winter's darkness.

And volunteer in the kitchen when there's stuff to peel.
It'll be good for you.

- Scott

Kill It With Fire, Part Five: Cleaning the kitchens. . . summary and wrapup

"Cooking is a craft, I like to think, and a good cook is a craftsman -- not an artist. There's nothing wrong with that: the great cathedrals of Europe were built by craftsmen -- though not designed by them. Practicing your craft in expert fashion is noble, honorable and satisfying."

- Anthony Bourdain, Kitchen Confidential

This blog began with that quote.

No one begins something like this on a whim. And if I'm honest, the quote that started this insanity was just one of many pebbles that contributed to the avalanche. It might have been the first pebble, but I can hardly blame Mssr. Bourdain for all that followed...

I am tired. More tired than I have been in a long, long time. My new regimen of archery practice didn't help, and for my Elizabethan alter-ego, the invention of Advil is 390-odd years in the future.

Thankfully, I live in that future so I'm not reduced to gnawing on the trunk of the nearest willow tree.

I was an art major, which is a roundabout way of saying that I spent a lot of time working in restaurant kitchens. There wasn't much in Bourdain's book that really surprised me. Of all the oddball jobs I took through the 'starving artist years' that are so fondly spoken of by people who've never lived through them, the restaurant jobs were my favorites.

Was it noble, honorable, and satisfying, as he promised? I dunno. I wasn't a chef, the highest I ever got was prep cook. I certainly didn't make it to culinary school; I spent too much time as a dish dog, really. Nevertheless, the exposure to finer foods and the people who prepared them than I could afford on what they were paying me taught me to appreciate, to taste, food differently.

But this isn't a foodie blog any more than it's intended to be Scottie Goes to Ren Faire. I never really meant for the baking demonstrations at the Washington Midsummer's Renaissance Faire to change so drastically how I thought about this project.

I'm still slightly ashamed to admit that it didn't occur to me earlier to set up and attempt one of these trades at anything close to full production level.  How could I ever hope to understand the lives of my craftsmen forebears if I never stepped fully into their shoes?

We'll get to shoes soon, this is about... I almost said it's about bread. It's actually not at all about bread.  Anthony was right about that. It's about craft.

The WMRF demonstrations were always intended to be a sort of safety valve on this project. The faire was scheduled just past the midpoint in the project and I knew that by that time I'd have a fair idea whether or not I thought I'd make it by the end of December. (Though to be honest, I still don't know and you'll see why I've stacked projects as I have in the coming months.)

Like archery, baking was not something I ever thought to enjoy. In my home, I do all the cooking, but The Engineer did all the baking. Baking was too fussy for me, too much like science and not enough like art... or so I thought. It never occured to me that it would be baking that finally put me over to the noble, honorable, and satisfying side of the kitchens.

Those are The Engineer's hands in that photo above. It was also the first time in quite awhile that she and I cooked anything together. Until the recent remodel began, our kitchen was inhospitable to more than one person at a time.

There's finally room for craftsmanship. 

Photo & Digital Manipulation by Dan Hill - © 2013 Used with permission

By God, Tony was right about that. When Dan Hill posted that photo manip above, one of the first comments posted below it (by someone I have never met, mind you) was two words: "Naturally happy."

Bourdain spent the rest of Kitchen Confidential talking about how dog tired he got working the line, how strung out he was on various substances, how much the food business was a scam and how much was genuine, and how arduous the restaurant biz is is, but even now you can see in his shows how much he loved it.

I'm starting to feel that way about bread and baking.

Baking turned out to be more art than science, not as slavishly dedicated to the arcane formulae of moth-eaten texts as I once believed. When my hands were in the dough and our friend Becky had the ovens blazing and Kristin was scooping flour into the bowls while Becky's husband Douglas was working the rope line, charming the tourists with his English accent and well-rehearsed dialogue about the history of English baking... here was an element of jazz. 

And always the crowds lined up at the edge of our area, asking questions and carrying away my card or the address of this blog scribbled on a bit of paper. At one point, we scrawled a diagram and the URL for this project on a chalkboard and folks were taking photos of it with their phones.

I hope you found your way here without any trouble. I hope that you learned something that day at the faire when you stumbled across our mad adventure in the land of yeast and flour. God knows that we certainly did.

That Corgi was an excellent student...

The Oven's End...

The oven at the Washington Midsummer's Renaissance Faire site was never meant to last. Not only did we build it from the cheapest materials, we taxed them to their uttermost extremes. By the end of the last day of the fair, the cracks were no longer superficial. The ceiling and the framing around the door were beginning to deteriorate and I decided to bake a few final pies and call it a day.

We let the oven cool and went our separate ways to enjoy the fun and frivolity that we'd missed the other weekends of the faire due to tending our breads.  When the final cannon sounded the end of the faire, we gathered one last time around our hearth...

The Engineer had the honor of the first whack.

Then Becky and Douglas, who were so eager to leave they were already changed into civilian clothes...

Then it was left to me. It felt a little wrong, like putting down a family pet. It had stood us in good stead, generated far in excess of its capacity and kept going strong. But the heat and desolation of the days standing in front of it got the better of me and I let the hammer swing.

And soon it was all over.  It arrived at the faire site in buckets and would leave by the shovel full, loaded in the bed of my truck...

The final tally for our little wood-fired bakery: 220 loaves, eight pies, nine scones, two loaves of soda bread, and 1 apple tart, utilizing 1/2 bushel of apples, 80+ lbs of flour, and several gallons of ale. 

Thanks to my partners in floury crime: Kristin Perkins, Kelsey Fahy, and Becky & Douglas Norton. Thank you to Pat, Tracy, and Amy of the Washington Renaissance Arts & Entertainment Society (WRAES) and all the cast and crew of the Washington Midsummer Renaissance Faire.  I hope you enjoyed the bread we dispersed to your tables each day from our bakery.  Thank you to all the photographers that documented the events and kindly sent me their photographs and videos.

There is, as always a sense of melancholy as we end one thing, and a sense of hope as we embark on the next.

Stay tuned to this channel. I doubt this is the last time we will see the fruit of an oven such as this. I still have the one in my back yard, after all...

~ Scott