I've been helping out at Whitman Boys Manufacturing this week. All of the moldings, trim and doors for a house are created by one or two people operating small saws or sanders. Each piece is finished by hand in a multi-step process depending on the type of wood and its intended purpose.
Almost every part of the waste stream from the mill is recycled. Sawdust is hauled to a nearby farm and turned into compost. Scrap lumber is used to heat several homes and the farmer's greenhouses. Used lacquer is collected in a small covered bucket and taken to a waste disposal facility. At a time when global manufacturing has moved overseas, here at home, artisan lumber mills, like wool mills, are making a comeback and offering a high quality product at an affordable price using recycled materials in an environmentally responsible manner. I'm proud to be a part of this movement.
Here we are taking some old cedar fence posts, running them through the saw and making boards which will be used for the living room ceiling. First each fence post is screened with a metal detector in order to remove nails which will damage the saw and potentially be thrown out of the machine into the workspace. Then the boards are fed one at a time through the saw and stacked on a cart.
Changing the blade on the saw.
The old blade will be sent out for sharpening and reused.
Here's some old barnwood getting a light resurfacing, refinishing, and then being re-purposed for flooring and cabinet faces. Wouldn't this be beautiful under a comfy rocking chair and knitting basket?
My part? To hand-dye alder moldings and cabinet trim for the new house.
After applying the stain by hand to each board, two coats of sealant are applied, then I hand buff each piece, then it receives it's final coat of sealant, another buffing and is then ready for the carpenters to install.
Today these boards are having the sealant applied, so I'm home working on the yarn store. Tomorrow I'll go back and hand rub each board until it shines with a beautiful depth of color and silky finish. I was going to say it's just like dyeing yarn, but in fact, it's nothing like dyeing yarn. Yarn is squishy, boards are not. Yarn can be dyed many, many colors, boards, for some reason, are almost always some variation of brown. Hmmmm. Wouldn't it be lovely to have moldings done in the Many Glacier colorway? What is similar for me is the rhythm of the work, the attention to detail that is required and the pleasure at the end of the day of looking at the finished stack of work and feeling proud of it.
If anyone wants some new flooring, moldings, ceiling boards, or doors send me an email at shelly at butternutwoolens dot com. Every new mill order will come with a free basket of knitting yarn to set beside your favorite chair. Even if you want brown instead of multicolor molding, although I can't imagine why you would.
Sock yarns will be posted into the online store tomorrow.