Permanence

A Huon Pine, native only to the Island of Tasmania

Serit arbores quae alteri seculo prosint – “He that plants trees labours for future generations.”

Caecilius Statius, quoted by Cicero. Motto of John Quincy Adams and his family, among others

This is a guest post by Dr. Antone Martinho-Truswell regarding a highly unusual tree, his adventures working its wood, and his thoughts about permanence. Enjoy.

What Does It Mean to Build Permanence?

Woodworkers – and especially we odder, curmudgeonly, hand tool woodworkers – have a vexed relationship with permanence. 

On the one hand, spend any time reading, listening, or talking to a woodworker of any integrity (not least our distinguished host, Mr. Covington), and you will inevitably hear about building things that last, creating furniture or structures that will outlive the creator. Or else you might hear lamentation of the impermanent, throw-away culture represented by particle board, OSB, melamine, wire nails, and so forth and so on. Stan writes regularly here about building for future generations, about tool chests that preserve and workshop stools that endure. When we chop a mortice or fit a dovetail, the idea is that the end product is permanent – the strength and durability of the outcome justifying the labour-intensive process of creating it

And yet: wood. We are not stonemasons. We are not goldsmiths. We work with a biological material, one subject to biological processes such as mold, rot, borers, gnawing things, weather, sunlight, fire and friction which eat and wear away at wood until it’s gone. Japan’s venerable old wooden structures, record holders across all human construction efforts, pale in age compared to those made of stone. Wood perishes as do all living things (at least since Valinor was sundered from the sphere of the Earth).

This is the story of a permanent wood. A wood as magnificent as it is rare, a wood that is itself a lesson in permanence, and my attempts to make beautiful things for now and the future.

Old and Young Places

I like to think about old things. I was born and grew up in Southern California, where almost everything is new, even the old things. I remember as a child a small water tower near my elementary school, proudly fronted by a sign announcing that it was the oldest building in the area – an august 25 years old. The tower is older now and so am I, but there were old trees around even then. Up north, there are sequoias and redwoods, and of course, the oldest of all, bristlecone pines. I was young then, and didn’t think too much about wood or lumber, but I knew the trees were old. 

As a young man, I moved to England for graduate school, and the world was much older. There was a sense of permanence, in the material things at least: old buildings and old furniture and old books and old wood. Oaken chapel pews and blanket chests and linenfold panelling – the sorts of adornments that, in the USA, are the enviable preserve of grand old institutions in grand old East coast cities, but in the UK, found in all manner of great and humble places. But the trees weren’t so old. England’s ‘green and pleasant land’ is green with farms and fens, but not so much old forest anymore. Like much of Europe, over aeons humans have harvested so much timber that little old-growth forest remains, only secondary growth, coppices and managed woodland. The trees in England are fairly young because the culture is relatively old. I was not yet a woodworker, and I did’nt think much on trees and timber at the time, but I knew the culture was old.

As a married man, I moved to Australia, and here I remain. The prevailing culture – that of the settlers rather than the indigenous people of Australia – is young, and so are the trees. Mostly.

Australia’s frequent natural fires mean that most of the trees that grow here are adapted to grow fast and big, but not long. Generations of forest turn over quickly – in ecological terms that is – with bushfires killing off adult trees and causing their scattered seeds to germinate and grow a generation of newer, younger trees. What’s more, as in America, the brash, youthful settler culture did not have a good track record as stewards of the natural gifts of the island continent, and the few old hardwood forests that once existed have been over-exploited. 

Perhaps with age comes wisdom, but now I am both a father and a woodworker, and I ponder permanence, and wood, a great deal, and what all this youthful forest means for woodworking here in the sunburnt country. 

Hard, Stringy Wood

If you know anything about Australian woods, you know they have a well-deserved reputation for being really, really hard.

The vast majority of our forests and the trees that grow in them are the various and many species of eucalyptus and its near relatives, with two qualities that make them a mixed blessing to woodworkers.

First, they are fast growing, so as to quickly repopulate the land after fire, and second, they are extremely hard – the softest commercially available eucalyptus wood is called “Victorian Ash” (or “Tasmanian Oak” – same wood, different source) in the timber trade with a hardness similar to white oak or rock maple. The hardness of other varieties can easily range up into ipe and ebony territory.

Rainbow Eucalyptus

The result is an abundance of eucalyptus wood great for things like flooring and fenceposts, but fast growth makes it especially stringy, which together with phenomenal hardness makes it difficult to work with handtools. That same Victorian ash, the most common of all hardwoods in commercial use here, is among the best behaved, and a straight grained piece can take a nice glassy finish from a hand-plane, but we have nothing commonly available with the smooth texture of a maple or beech. Victorian ash works like oak at best. The other good furniture eucalypt is Jarrah, which is a lovely orange-brown colour and less splintery than most, but it’s expensive and a good bit harder than maple, so still a challenge. Moreover, it comes from Western Australia, which, along with Victoria, banned all native forestry at the start of 2024, so it is likely to recede to only niche use in the future. 

There are many other beautiful, softer, easier working, and often fragrant Australian hardwoods, but for one reason or another all of them are scarce and hard to track down.

There are few species under plantation production here, and the fast-growing eucalypts crowd out most other species in our forests, so the best cabinetry timbers, like acacias and mahogany relatives, are rare. If you find these timbers for sale, it’s usually from a small-time operation that harvested a fallen tree – so you have to wait around for luck to smile on you. I try to snap up Australian Rosewood priced reasonably. The vast tracts of cabinet timber we once had – the famed Australian Red Cedar, which is actually a mahogany cousin, for example – were all irresponsibly exploited down to commercial extinction decades ago. A permanent culture of wood use requires a forestry industry with an eye toward permanence, which we didn’t have for a long time, and many argue we still don’t – hence the aforementioned bans and the limited selection of commercial wood. 

A few government agencies and private companies are trying to improve sustainable forestry in Australia focusing on Australian blackwood (Acacia melanoxylon). This species should not be confused with the African blackwood of oboe, clarinet and bagpipe fame. Australian blackwood is a dead ringer for Hawaiian koa, and is its closest living relative. It has a rich, deep, brown colour with the same gleaming chatoyancy of koa, but its name comes not from the colour of the seasoned wood, but rather the black color the sap turns sawyers’ hands.

It’s a breathtaking timber deserving of widespread admiration, and one of the few beautiful cabinet timbers down here that weren’t over-exploited to near extinction in the last century. The blackwood timber industry is apparently a bit wiser than their forebears, and so harvests less and charges more to promote sustainability. It’s the nicest timber that can be bought here straightforwardly, and is priced accordingly.

The Ships that Took Our Trees

Clipper Ship, City of Adelaide, 1000 tons

Of particular interest to users of Japanese tools and Japanese woodworking methods and mindsets are softwoods, and this is where Australia is confusing. There are no true pines native to any part of the Southern Hemisphere – but settlers insisted on naming all the fascinating and unusual softwoods down here “pines” – and then importing a northern hemisphere species for most of our plantation wood.

Norfolk Island Pine

Norfolk Island Pine

When Britain established the first penal colony at Sydney in 1787, the site was chosen partly because it was thought to offer a good strategic back-up to the British claims on Norfolk Island – a speck 900 miles out into the Pacific. The trees covering this island – Norfolk Island pines – were thought to be particularly valuable to the Royal Navy, as they tended to produce ramrod-straight single trunks, almost as if replacement masts had been conjured up from the Earth. However, the timber proved too flexible for masts, and the idea was abandoned, though the Norfolk pines got their second act as a popular ornamental plant (including a few all the way back in my home town in California).

Hoop Pine

Much more useful is hoop pine, a near cousin of the norfolk pine that grows on the Australian mainland, and is our only plantation-grown native conifer. I’ve made shoji from hoop pine; it has nice straight grain producing a good shine when hand-planed. The only other commercially available native softwood is Australian white cypress which has a beautiful smell and is famously insect resistant, but unlike most softwoods it’s harder than American oaks. It also doesn’t grow very big, so is mostly used for knotty, sapwood-sapwood edged fence posts, or equally knotty floorboards and decking. I understand that it is not a sustainably managed species, and conservationists often recommend against its use. 

Monterey Pine

The Australian construction industry relies on plantation grown monterey pine (also called radiata or pinus radiata) for all of its general purpose lumber. This is an import from California, now very rare in its natural habitat but grown all over the Southern Hemisphere to compensate for a dearth of native pine species. It is a particular pet-hate of Australian woodworkers, in online forums and general conversation, who lament its often crumbly texture and poor strength. I don’t hate it though – it can take a lovely plane finish and the wide grain does make for beautiful patterns on clear, flat sawn boards.

Huon Pine

Like all Australian trees, huon pine is misnamed. It isn’t a pine at all but rather the only member of its genus – more akin to a cypress than anything else, yet still not a cypress, a thing of its own. 

Fans of Tolkien’s works may lament that its name is Huon and not Huorn, but no tree was ever more deserving of association with Tolkien’s tree-herding Ents, that ancient race of sentient defenders of the forest.

Huon pines grow only in Tasmania, and only in the wet and mountainous western regions protected from fires. Provided they have that protection, they may achieve something most Australian trees do not – great age. Huon pines grow incredibly slowly, barely thickening as century after century wash over them, living at least 2000-3000 years, with some thought to be even older. This is best evidenced in the astonishing tightness of their annual growth rings. It is not uncommon to see specimens with annual growth less than half a millimetre – or to put it another way, the trees gain less than two inches of trunk radius per century. While immensely slow, these trees can still grow immensely large when given that precious critical thing – time. They are probably the longest-lived trees in the Southern hemisphere, and certainly in Australia.

There are lots of small huon pines growing now, though few big ones. They should be huge, but they are not, because the great ones were all mostly cut down to build boats – a vast fleet of huon pine watercraft were constructed in Tasmania, using up most of the big trees. The promise of the perfect tree for shipbuilding that had fallen flat on Norfolk Island paid off big time in Tasmania with the huon pine. The reason for the single-minded use of these ancient trees for shipbuilding will become obvious, but as a result of this hasty zeal, they are now the single most protected species of tree in Australia, both to allow the forest, with Ent-like patience, to recover, and to preserve the few very old and very large specimens that remain. 

Beyond the Grey Rain-curtain

These trees are old, though their lives are but the beginning, and death, as Gandalf once taught young Peregrin Took before a fateful battle, is just another path beyond which the journey does not end. This is, cynically, true of all wood that gets put to human purpose, but it is true in a special way for huon pines because of a unique chemical in their wood. Not unlike other fragrant cypress-like softwoods – including Japanese hinoki – huon pines contain great amounts of oil, in this case, an oil called methyl eugenol that protects them from insects and other wood-hungry nasties. Methyl eugenol is, as it happens, the ticket to eternity for wood. 

For whatever reason, methyl eugenol, in the very high concentrations in which it is found in huon pine, is astonishingly successful at preserving timber. Huon pine timber is highly prized for shipbuilding because it’s easy to bend and work, completely impervious to insects and fungus, and readily survives the rigors of the aquatic environment. All that ever seems to happen to huon pine is that the surface turns grey in the sun – much like teak. And then it simply endures. 

And I mean it endures. The 3,000-year age of living huon pines is one thing, but researchers have found fallen huon pine logs on the floor of the forest that have lain there, unmolested by decay, for as much as 38,000 years! Not petrified, not fossilized, just oily wood under a weathered surface, simply enduring. 

These characteristics are also why we still have a bit of precious huon pine timber available nowadays, reclaimed from time to time from old boats and old furniture, as durable and enduring as ever. Moreover, the foresight that was missing when the trees were mostly cut down a century ago was not blind when hydroelectric dams came to Tasmania. In the 1970s, with two valleys set to be flooded, the Tasmanian government allowed loggers to go into the valleys and cut down the pines – but not to take them. The loggers, working in tall boots even as the dam waters were rising, would leave the logs where they fell, to float up to the surface of the new lake as the waters rose. 

That was 50 years ago – the logs are still there, floating on the lake. The outer layer turns grey to about 1-2mm in, and then, inside, the creamy golden wood, as perfect as the day it was felled, endures. The decades afloat harms it not at all, and every year a tiny portion is licensed to be taken for restoration and preservation jobs.

This is all the unreclaimed huon pine that there is or ever will be for woodworkers to use, and they estimate they have about 50 years’ worth left at current extraction rates. But with the wood so impervious and eternal, what is already in cabinets and drawers and tables and ships will continue to circulate and be reused. It is a wood with true permanence.

An Unexpected Responsibility

At this point I will enter the story to share the most harrowing and rewarding of my experiences as a woodworker.

By chance, I had the opportunity to acquire three large slabs of huon pine, cut and dried in ages past but never used. Compared to the tiny crafting boards and turning blanks that are generally available (at great price), this was a bit of a windfall. I could have, with all cynicism, listed each one for sale for several hundred dollars, pocketed the profits, and went on to buy more quotidian woods. I did not do this for two reasons.

First, and perhaps most pointedly, with visions of epoxy pours and hairpin legs plaguing my dreams, I was overcome with a sense of responsibility to “protect” this precious wood – whatever that means. I wish to acknowledge, in self-reflection and humility, that I am an amateur woodworker. A reasonably experienced and meticulous one – but an amateur nonetheless, albeit one who works with hand tools and has the hand tool mindset. My work is fine but not perfect. But I suppose I like to think that the tool marks I leave here and there, occasional tear-out, and other mistakes that remain have a certain honesty and worthiness to them, becoming of a slab of great age. Vanity of vanities, all is vanity…

More than that though, I saw in these slabs of huon pine, and in the legends of these trees, an opportunity for permanence. Here were three great hulking slabs of a tree older than the nation-state it was felled in (I counted 800 growth rings on one of the slabs – and it wasn’t even a centre slab), thick and strong, and made of the closest wood comes to being an imperishable material. Here was the opportunity, if it was ever going to exist, for a piece of furniture that might outlive the memory of my name. 

It had to be a table. Only a table could use to best effect the wide expanses of precious wood – laying them out on full display for all who saw them to admire. No matter how perfectly I might make a cabinet or chest, it would not do justice to the material. And, as history, archaeology, and literature show, only a table is so intimately connected to life and family and holiness by its proximity to hungry mouths, little hands, and eager minds as they first do their colouring and then their maths homework, and then their college applications. Only a table is ever so truly loved by generations as to be worthy of wood older than all those generations combined. I simply couldn’t bear cutting the beautiful slabs into small pieces. So for months I fretted; and worried; and stressed about the crushing responsibility of making the first cuts. 

The Weight of History

I am an apartment woodworker. My family home is a house in the mountains west of Sydney, but I work as Dean of a university college and we live most of the time in the Dean’s residence, an apartment on campus. I am blessed with a very patient and indulgent wife and an apartment that happens to have a sort of wide corridor I use as a tiny woodshop. Space is still limited, though, and I try not to stockpile wood (in the interest of stockpiling tools – ahem). So, three slabs, two metres long and the best part of a metre wide, mocked me each time I had to shuffle past them. And still, I fretted. 

I eventually decided upon a refectory table so that no matter how many chairs are crammed around it, none clash with the legs. And with a strong stretcher tusk-tenoned into each leg to allow it to knock down, so that I could make it big but still fit it through doorways. Most importantly, I needed to keep the two 800mm wide boards that made the tabletop flat – so sliding dovetails across the bottom to counteract any cupping. And those sliding dovetails would be a perfect place to pin the top to the legs, with removable dowels, again so it could be knocked down to move. Drawbored mortise and tenon joints to hold the I-shaped legs together without glue (since all that wonderful oil makes gluing troublesome anyway). A kanna-shiage (handplane finished) top for beauty and touch, with just a light coat of oil and hard wax, so that the wood itself can be appreciated. A magnificent vision. Complex and well-chosen joinery. Perfection worthy of the tree. Entirely beyond my experience or skills…

I had to start by getting to know the wood. Before any cutting or marking or anything, I realized I could not confront the massive task I had set myself without first knowing what it was to get huon pine under saw and plane, to see, feel it, and smell it.

.

 

I hoisted one of the slabs onto my sawhorses, and with a few strokes of the little aogami roughing plane on the left, and a few more of the shirogami finishing plane on the right, I had my first look at the slab, and my first curls of huon pine shavings. (No, Stan, I don’t London finish my plane bodies. They are dirty, it’s patina.)

The smell – oh the smell. The smell of huon pine is unlike anything I have ever experienced. It is sweet and rich and almost creamy, but without even a hint of sugariness or caramel, nor any of the medicinal notes of cedars or cypress. I suppose the aroma is a little like gardenia flowers, but different. And it’s persistent. I saved bags of little offcuts that are no less fragrant now than a year ago. 

The scent was such that I almost did not notice the figure at first. From some angles, nothing more than a very tightly grained, golden softwood, with rippling grain caused by the irregular growth of the tree’s surface over the centuries is visible. But when the light strikes the surface of the top at the right angle, a shimmering sea of lamellar rays cutting across the grain pop out, almost obscuring the grain with its gleam. Beautiful but subtle – much like the scent. This image and this aroma is now linked with permanence in my senses.

With the feel, smell and appearance of the wood now embedded in my mind I began to feel more confident about beginning my table project. One serious concern remained, however, namely: tear-out.

Layout That Fills the Workshop

I started in with trepidation, hoisting the two closest matched slabs onto my horses and getting to work. In my little shop, I have no room for a great big assembly table, so the slab was my workbench, and took up the whole shop. Here you can see my cramped little shop, replete with little atedai against the wall, assorted tat taped and hung on the walls (including my Palm Sunday palm, awaiting the coming Ash Wednesday), my tool chest brusquely stolen from Stan’s design, and a lovely old tansu filled with bric-a-brac.

Layout was painstaking, although not because the joinery was especially complex. Before shaping, the two “I” shaped legs were six simple boards and the stretcher would resemble nothing so much as a 2×4. The only complexity to the initial layout arose from the graceful radius I had planned for the long edges of the two top slabs. I could have cut them with straight edges and cut the curved edges later but that problem would have been unnecessarily wasteful. 

One simply cannot waste this wood. If you have any respect or regard for the trees that support our craft, it repulses the conscience to even put plane shavings into shop bins. Moreover, I absolutely refused to cut these slabs in anything but the most efficient, offcut-preserving way. As a result, layout took days (or, rather, nights. Amateur, remember?).

The two surfaces of the slabs I used for the top each had unique flaws and virtues. In the end, curving the tabletop’s edges to accommodate the natural edges and features of the slabs proved effective in maximizing the tabletop’s size while minimizing waste of this rare and valuable wood. For example, in the photo above you can see where the near right corner of the slab narrows towards the end, an inconsistency my layout had to accommodate. This layout was also necessary because two of the slabs were contiguous in the bole and one was not, such that the two contiguous, matched slabs had to be used for the top even though one was somewhat larger than the other.

Dealing with the constraints that imposed this layout taught me important lessons in collaborating and compromising with the wood. In line with Japanese tradition, I knew I wanted the “outside” surface of the board to be oriented upwards in the table, and so my layout prioritized that side. As a result, both slabs ended up with prominent natural flaws on the underside – like greyed areas, bark incursions, and even one gash that looked as though the tree had been struck with a red hot poker.

There is a school of thought in modern, machine assisted, YouTube recorded woodworking that cannot tolerate such defects, no matter how small or natural, in any piece of furniture, demanding they be either removed entirely or filled with colored epoxy. The first approach I reject because wood is natural and I believe it should feel natural. I enjoy the fragrance of the wood, and the feel of running my hand along the underside of the table, sensing the evidence of the tree’s story, together with the tool marks I intentionally left. The latter approach I reject because epoxy is plastic, and I work with wood. The table bears the scars it earned in life, but only reveals them to those with enough appreciation and humility to get down on their hands and knees to gaze upon them. 

Putting Blade to Wood   

I do not now, and suspect I never will, own a table saw. Someday I might own a bandsaw, but I’m not convinced. In any case, I won’t have any of these things in the house whilst my daughters are young, as much to spare my family’s lungs from dust as to avoid injuries, however unlikely. 

So that meant I had to figure out a way to accurately break down these slabs along my layout lines with hand saws, in a room that barely contained the slabs. 

I couldn’t do it on the sawhorses – that would require me to stand on the slabs to make the long rip cuts, which seemed risky to their integrity without a supporting table underneath, especially when sawing the narrower pieces. And the slabs were too long and too heavy to comfortably use the Japanese low horse and foot-clamp method, which I am normally fond of for long rips.

The solution I selected was to support the slabs horizontally on one long edge using my 6-inch thick planing beam, with the other long edge supported on low horses with extra boards taped to them to make up the difference in height. This provided enough vertical clearance under the slab for a kataba saw. This arrangement had other advantages too. As I ripped from one end of the slab to the other, I could stand on the slab directly above the supporting planing beam, which was in turn resting on the floor, preventing the slab from shifting position while avoiding downward deflection of the ever-narrowing slabs.

My back did not love this hunched sawing position, but it was more comfortable than you might expect, and in two long sessions of rip-sawing, I had everything broken down to pieces: two wide top planks, each tapered on one edge, two vertical leg pieces, four feet and aprons for the I-shaped legs, and one long stretcher. As it happened (and as you can see below) the offcut from the third slab was almost a perfect extra stretcher. I still have it and will use it for something someday. It is the world’s most magnificent (and I suspect valuable) pine 2×4. The two venerable katabas, one rip and one crosscut, may be seen taking a well-deserved rest after rendering magnificent service. 

With designing, planning, layout and rough cutting done the project shifted to the shaping and joining phase requiring greater attention, so I put down the camera, and did not pick it up again until the job was done. Sadly, I don’t have photos of gorgeous shavings rippling off planes, or of the massive Anaya-nomi I used to cut the mortises for the stretcher to pass through the legs, or of the nakin-kanna rounding off edges. 

This work was more-or-less conventional furniture-making; taking the neatly rectangular pieces of wood I made in the rip-fest above and shaping them into components using good steel and keen eye. I didn’t follow a borrowed or historic pattern for any of this, but worked out my own take on the refectory style of dining table with two I-shaped legs and a single stretcher.

I made a pattern of a single asymmetric curve using a bit of sturdy brown paper shopping bag, leaving the carry handle attached to hang it on my shop wall throughout the process so it was always to hand. I used this same curved pattern throughout to define all the curves in the project, starting with the concave slope from the mortise in the feet to their toes, the tapers from centre to ends on the vertical legs, and again as the most important curve in the project – the gentle swell of the tabletop’s long edges from one end to the middle and then tapering back to the opposite end again. 

Once the base was completed, the conventional woodworking ended and the real gauntlet began – the top. 

The top was made with the two long, wide boards shown with my kataba saws in the photo above. At almost 400mm wide each, they were a challenge to handle, a bigger challenge to plane, and an even bigger challenge to keep flat. 

The work of planing the wood went alright. The swirly grain of huon pine is not terribly prone to tearout, and like all quality softwoods, is a joy to plane in the direction to which it agrees, producing shimmery, breathtaking surfaces. The trouble is that each 400mm board contained 800 years of growth rings with grain direction changing within each board many times due to storms, cool summers, and a lightning strike or two as empires rose and fell. And with such tight grain an entire century of growth, along with the changes in the tree’s environment that impacted that growth, ended up recorded within a mere five centimetres of width – narrower than the thickness of a standard 70mm kanna – and often without apparent visual clues. As a result, seemingly neat, fine ribbons of shavings pulled end to end would be followed by tiny but significant tearout here and there across the board. 

Reader, this took days – days of sharpening by very best white #1, fine mouthed, perfectly (amateur-perfect, mind you) tuned kanna. Days of shaving just exactly to this specific point, in just this direction, just so, to clear up a spot of tear out, then switching sides and going the other way, hoping and praying and watching that I didn’t overstep the boundary and have to start over – which I did, many times. And all the while, awkwardly walking around the massive slab, leaning over it to plane the far side, getting half up onto it like a billiards player, and then doing it all over again on the other slab. There is still some tear out in the surface, especially around the teardrop-shaped bark inclusion that gracefully adorns one corner of the tabletop. But it’s pretty close.

Keeping it Flat

An important aspect of the project was ensuring the wide, solid-wood tabletop remained permanently flat through changes in temperature, humidity, loading and coverings. In the case of such wide slabs, there was only one realistic solution – sliding dovetailed battens on the underside. This design detail had the advantage of providing two level, perpendicular surfaces to connect the legs to the tabletop.

Of course, a hard cross-grain connection between the battens and the tabletop using glue and screws would end in tears after just a few years, so I cut two blind sliding dovetail slots in each half of the tabletop beginning at centre joint of the toward to about 8-10cm of the edges, then cut dovetails into the battens to fit. The two planks hold the battens captive between them once installed, and the friction in the sliding dovetails locks the two slabs together without glue, dowels or hardware.

To use glue anywhere in this project seemed wrong. In any case, the oils in huon pine don’t play nicely with glue, and the joinery connections were the better plan. 

I cut the dovetails in the battens and tabletop planks using my cleverest of all Japanese planes – the male and female dovetail plane, a rare beast indeed.

With the battens installed I cut 10cm wide shallow bevels on all four lower edges of the top, tapering the top to create the illusion of a tabletop only 20mm thick from a slab about 40mm thick in the centre. This involved a lot of plane work.

I left the underside a bit more rustic, even allowing large areas of “live” bark to remain as a lagniappe to the worshipful person who surveys the underside. You might think that leaving bark on the underside meant that I contravened the usual practice of Japanese woodworkers of using the outside surface of a plank as the show surface, but no – though not Japanese, I cleave to this principle invariably, but in this case, the history of the tree involved so many twists and turns that the bark inclusion was exposed on the inner surface of the board.

For clarity, allow me to explain what may not be obvious from the photos. The two legs are connected by mortise and tenon joints to horizontal feet at their lower ends and horizontal beams at their upper ends. In turn, the trestle leg beams are connected to the two battens by four dowels, two at each batten, that pass through the beams and battens at an upwards angle. After exiting the batten, the end of each dowel presses tightly against the underside of the tabletop, slightly bending and binding it in place. 

To disassemble the table in preparation for relocating it to our home in the mountains outside Sydney, I just need to knock out these four dowels and slide the battens out of their dovetail slots, and knock out the two wedges in the ends of the tusk tenons securing the spreader beam connecting the legs. This design has worked well, and the dowels are strong enough that the table can be lifted and carried by the top alone.

The Finish

Now, a great part of me wanted to leave the wood unfinished, both to enjoy the raw kanna-shiage surface, and to ensure the magnificent smell would not be diminished. But, to provide some protection and give a bit of extra visibility to the lovely grain, I gave the wood a couple of coats of thinned pure natural tung oil, and then rubbed on and buffed out several coats of carnauba wax creating a surface hard enough to help protect the relatively soft wood from dings and scratches. Also, my wife liked the colour better oiled than unfinished, a very important consideration for all of my woodworking efforts.

And that was the job done, and here it is, in its home on the covered veranda of my house:

As you can see, the finish turned the feet, which I cut from a discontiguous slab, a darker color than the rest of the table, but it’s an effect I rather like. The clouded figure of the top shimmers beautifully in the morning light from the East, and the little imperfections quietly witness to handwork, something for me to fret over in my quietude at meals around the table. The horizontal beams at the top of each leg that mate with the battens, not visible in the photos, are identical to the feet, except of course inverted.

I do not think I am testing the permanent nature of this table by using it outdoors  – though I may move it inside for a different practical reason: it is now the largest table we have, and has already made a couple of trips inside for big family gatherings. Rather, faced with a true forever wood that can endure against the elements, it seems only right that it should experience them and demonstrate its aplomb. I am glad in the end that I did not glue the centre joint of the top surface because it allows the two slabs to move and stretch a bit on humid days without cracking or busting the seam, and while this does mean they become un-flush for a day or two, they settle back in becoming flush once again when the weather dries out. The table can breathe. 

I will inevitably make little corrections as the table and I get used to each other. I remain unsatisfied with the very rectangular shape of the stretcher, and when the time comes to break down and refinish the table I will add some curvature to the stretcher. I will also probably resurface the top perhaps once a decade, as it ages and my skill with a kanna (hopefully) improves. Part of the joy of using a wood that should outlive my bloodline to make a table of great permanence that can be disassembled and reassembled as needed is the anticipation of ongoing minor improvements, and the relationship I and future generations will have with it. 

In the end, I still do not quite deserve this wood, because no one does. It is right and just that the Tasmanian government has banned the felling of any more of these trees, and it is right and just that the remaining wood is hard to come by and cherished. I am happy for the opportunity to make something permanent with this magnificently permanent and beautiful material. 

Antone Martinho-Truswell is a professional zoologist and amateur woodworker. His work can be found on Instagram at @stjosephwoodworks, where he posts his projects, experiments, and failures, and takes the odd commission. If you enjoy his writing and want to learn more about his day job, his book, The Parrot in the Mirror, is available from booksellers online and worldwide.

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The Japanese Floor Workbench (Atedai 当て台) by Dominic Campbell – Part 2

Good hip and knee flexibility is needed when working on the floor, but tabi socks are optional! Credit: D.Campbell

When a work lifts your spirits and inspires bold and noble thoughts in you, do not look for any other standard to judge by: the work is good, the product of a master craftsman.

Jean de la Bruyere

Introduction

Gentle Reader, welcome to this second installment in my series of articles about the Japanese floor workbench called the “Atedai.” In Part 1 we looked at some of the design considerations and construction techniques involved in making this tool. In this presentation we will get to the fun part of putting it to use.

These workbenches, as I hope you will see, are incredibly versatile tools that can be used in endless ways. My objective in this article is to show you a number of those methods, some traditional and some less so, and inspire you to maybe give it a go yourself. 

I will use examples from my own work, as well as examples from master craftsmen (including a few National Living Treasures of Japan) who have completed rigorous apprenticeships and used atedai professionally much longer than I ever will. 

I have not received any direct training in this method of working but have ‘stolen’ many ideas and methods (lit. “Gijutsu wo nusumu” 技術を盗む) through observation and practice of their techniques. 

This is the way traditional apprenticeships run in Japan – the master seldom gives direct instructions and entertains few questions, yet the apprentice is expected to learn everything – through observation and practice – and is thus said to “steal” his master’s techniques. Only in my case, my teachers are Stan, books, the internet, and videos! 

I will use a fair number of pictures and video links in this blog, as they will show much more nuance than words can about how master craftsmen use their Atedai.

Disclaimer

If you live in a ‘chair culture’ and are just starting to work lower to the ground, then this may be the first time you have sat cross-legged on the floor since school. Take it easy! Go slow, improve your flexibility gradually and your knees will thank you. This style of woodworking is physical, and you must orient your whole body with the work to be efficient, and safe, which at first can cause some aches and pains. Bear with it – the results will be worth a little suffering!

If the floor is out of the question, don’t despair! There are a number of ways to use an Atedai either sitting on a stool or standing, which we will explore in this article as well.

With that said, let’s begin!

When placed low on the floor, an atedai workbench is much, much bigger and more stable than a standard table-style workbench. Using a woven-reed goza mat, or other soft floor covering, you can convert any reasonable space into an efficient work area in a couple of minutes. The goza makes it easy to spread your tools around you within easy reach to keep the work going quickly. It also makes cleanup of woodchips, shavings and sawdust easy. And of course there’s no worry about tools being damaged by rolling off the workbench. Win-Win. Credit: D. Campbell

Sawing

Sawing using an atedai falls mainly into two categories – rough sawing for stock preparation, and precision sawing for finer work/joinery.

Rough sawing doesn’t differ much from using low sawhorses… you lay your work flat on the bench, making sure to hang it over the side, or off the far end of the bench, and use your foot to stabilize the board while your hands work the saw. This is very quick and accurate methodology, one that doesn’t require the large, bulky, difficult-to-store sawhorses typically used in the Western woodworking tradition, but it is dependent on using Japanese saws.

Cross-cutting lumber using a Japanese pull-saw and an atedai. The craftsman in these videos is a well known “sashimono-shi” named Kimura Tadashi. Credit: Kotaro Tanaka

The process of rough sawing is the same, more or less, as when using low sawhorses. Using one’s feet to stabilize the workpiece helps significantly. You can also stand with both feet on the stock, which can be very useful when making big rip cuts in large stock.

Fine sawing can be slightly ‘fussier’ in getting the work where it needs to be, and can depend on the kind of joint you are cutting. That said, it often helps to prop the work up somehow, particularly when ripping. This can be accomplished by leaning it vertically against the end of the Atedai, or laying the work flat on the bench (a clamp can help here) and propping up the end of the Atedai – experiment and see what works for you. I have seen craftsmen using plane blocks to prop up the near end of the bench – an ingenious and elegant solution, yet maybe not as quick as just leaning it on the end…

Another famous sashimono-shi, Mogami Toyojirou, leaning the work vertically into the end of the atedai to raise it off the bench to saw hidden mitred dovetails, a classical joint. Credit: Kotaro Tanaka

Note the size of the stops on Mr. Mogami’s atedai are much smaller than my own, and very much in the sashimono tradition.

Any cross cut, like the cutting of tenon shoulders, can be made off to the side of the bench or, if your stops are low enough, in the middle of the bench itself. I prefer to saw to one side, giving my arm room to move back and forward without having to shift position too much. You can also use shorter Western joinery saws here, by pushing the work into the stops, almost like a bench hook.

Planing

Planing at the Atedai is accomplished in only one or two positions… sitting down crossed legged, sometimes with one leg extended, or while on both knees. Give it a try and see what works best for you in your work.

You hold your plane in both hands, reach and pull. Simple.

In my experience, I have found that kneeling on both knees works best for powerful roughing strokes, because I can make use my upper body weight to press down on the workpiece while making powerful, controlled cutting strokes with the plane. Alternately, planing while sitting with one leg extended works best for me for finish planing. YMMV – experiment and find what works for you.

For really long stock you can, in theory, lunge forward with one leg and rock back with the planing stroke, but that still has a length limit (not to mention the need for very strong leg and back muscles) and standing up really has all the advantage in this situation. Traditionally, craftspeople such as Tategu-shi, joiners who specialize in doors and shoji, have a dedicated planing beam or bench on legs set up in their workshop, used standing, for longer stock preparation, and use their Atedai used for mortising and other smaller tasks.

Ono Showasai planing on both knees. Credit: 木工芸-大野昭和齋の指物わざ
Mr. Mogami planing with one leg extended. Credit:Kotaro Tanaka

“What about my Baileys?!” I hear you cry.

Fear not, Gentle Reader, for you can still use Western planes… both on the normal push stroke, as well as the pull… by adopting this work style. I often use No.5 and No.7 planes for initial rough stock preparation, and both can be used well low-down, although it must be said not quite as well as Japanese planes. To push I often kneel to the side, or sit on the work and push towards the stops. Maybe not elegant, but still good enough for me – either way, no one is watching, except maybe Master Sprocket, the neighbor’s cat, who meticulously supervises every step of my work!

Yes, you can use western planes on the floor. It’s maybe not as efficient without the use of your legs, but I have flattened tabletops on the floor with the help of a no. 5 and no. 7 plane. Have you tried pulling a western plane? It works surprisingly well! Just grab the knob with your left or right hand and place your other hand on the handle. Credit: D. Campbell
The honorable Master Sprocket come by for his daily inspection. He is a tough, but fair, task master that doesn’t judge my use of push planes at the low bench too harshly, so long as the work is completed on-time. Also instrumental in keeping the workshop pixies at bay. Credit: D. Campbell

Another way to use push planes is to stand the atedai on its side and clamp the workpiece to its face, which allows you to plane standing up… this can also be useful with Japanese planes when planing longer boards or when you just need to stretch your legs and rest your back.

By standing the atedai on its side, you can use push planes with ease. Remember to place the atedai on the side you don’t use to shoot with, in my case the left side. Credit: D. Campbell

Jigs for any number of planing tasks are used as much in the Japanese tradition as they are in the West for 45° and 90° angles and, except for being designed for the pull stroke, do not really differ. One jig, however that may be new to you is a rather simple, but incredibly effective, device helping to shoot long edges. It is simply a flat board with a stop, which elevates the board above the surface of the bench, allowing your plane to shoot the edge of a board. This is one of the reasons you will often see 2 stops rather than 1 long stop on the Atedai. One stop braces the shooting board and workpiece while the gap between the two stops allows the plane to pass through and finish the stroke.

Mr. Mogami planing the edge of this board with the help of a simple, but very useful, jig not often seen in Western woodworking. From the video linked to above. Credit:Kotaro Tanaka

Chisel Work

Just as when planing, there are a number of ways, and many more besides, to use chisels at an Atedai depending on the task at hand.

For mortising, and other similar tasks, a great way to hold the work is with your derrière. Yes, finally we come to the famous bum clamp. Sitting on your stock (while potentially uncomfortable on narrow or high stock) is one of the best ways to keep the work steady and both hands free for using tools while positioning yourself for efficient and safe work with your eye directly over the mortise to help ensure the chisel stays plumb. As we will see, this is also very effective while at a standing bench too.

The veritable bum clamp displayed here by Mr. Toshio Odate. Note the cushion – a long day mortising without it isn’t much fun – and the nihon mukoumachi nomi in his hand, a specialized dual-blade chisel for cutting double mortices. Credit: Popular Woodworking

Hollowing work, like that used in kurimono carving, is often performed while sitting to the side of the bench directing all the force into the stop, and keeping the work steady. Be warned here, keep a mental note of where your left knee is in relation to your chisel! In this position it’s easy to make powerful horizontal hammer blows, and the last thing you want is a chisel jumping out of the cut into your knee.

In this photo I am sitting at the side of the bench performing the heavy chisel work of hollowing. Impact forces are directed towards the stops, which is why I installed larger than average stops on my bench. In my previous post, I mentioned leaving the underside of my bench untouched – you can see the irregular thickness where the leg is dovetailed into the top. Credit: D. Campbell
Akira Murayama hollowing a tray made of keyaki wood (zelkova). Any similarity to my own work is purely coincidental! 😉 Note – in all these pictures, and videos to follow, you will see the oil pot is never far away. This is, IMHO, the most important tool you can own – I implore you to make one!

The final ‘standard’ chiselling position is at the end of the Atedai, often using your foot to stabilize the work piece, although clamps may also be used. This allows for quick repositioning of the workpiece, if needed, and holds the work solidly enough for the work at hand (foot?). As you tend to chisel more or less vertically in this position, your foot isn’t in much danger, but it still pays to be cognizant of the potential risk at all times.

Mr. Nakadai Zuishin using his foot to steady the workpiece. Note, you will often see the use of tightly-woven cotton tabi socks by craftsmen of all trades in Japan. While traditional, I also use them because normal cotton socks are like sawdust magnets, and my wife is fed up with hoovering the house! It also helps keep the stock clean, especially important in the finishing stages.

This is number 3 in a 9 video series of Mr. Nakadai, designated one of Japan’s National Living Treasures, making a beautiful serving bowl for the tea ceremony from pauwlonia wood. You can view the entire playlist on YouTube at this link.

Standing & Sitting

So far, we have looked at using the Atedai while it is resting on the floor, but there are a number of other ways to use it if your knees say “no”, or if you just prefer to work while standing up. 

A great way to integrate the planing bench into your normal workflow is to have a slightly smaller Atedai for use on top of your normal workbench. This can be a great option if you use a mixture of western and Japanese planes, and can give you the best of both worlds. If you dimension it so you can place the Atedai under your table workbench when not in use, you can quickly and easily pull it out when needed. 

A smaller atedai placed on top of a table workbenchj for planing while standing. Although smaller in dimensions, construction is the same. Note the slight angle towards the stopped end, which some prefer. Credit: Kiyoto Tanaka, a superb luthier https://www.youtube.com/watch?v=PQVqu3GRbQ0
If you prefer to sit on a stool when you work, an atedai placed on a lower table is the perfect solution. Credit: kougeihinjp https://www.youtube.com/watch?v=-Gkt3yrdZVw 

By placing the Atedai on sawhorses, you will have a versatile, and mobile workbench which, with some practice, will do everything you ask of it. Carpenters in the field will often use a bench similar to this, made with materials on site, although they can sometimes be rather quick and dirty affairs. 

In the photo above, Mr. Makoto Imai, a highly skilled carpenter, is using a similar set up, which was immortalised in ‘The Workbench Book’ by Scott Landis. The stop here is just a screw, which is all you need for most planing operations – although care must be taken if you don’t want to mark the end grain. I love the simplicity of this set up, and find Makoto’s work truly inspiring. Credit: Daiku Dojo http://www.daikudojo.org/Archive/20070414_tfgwc_asilomar_makoto_imai_demo/ 

While easier on the body in some respects, the lack of vises (Editor’s note: “virtually free of sin”) still means these workbenches require good flexibility and the use of body clamps. There is no escaping the fact that Japanese woodworking can be very physical. With that said, due to the need to lift your knee/leg up to, or to sit on, this kind of bench I have found the work surface needs to be slightly lower than your normal Western bench – for me about the height of my downward facing palm, with my arm by my side.

The traditional knee clamp holding the workpiece in place while mortising. This may look ungainly, but is surprisingly comfortable, and is a really quick and efficient way to work. This was my previous ‘workbench’, which I used a lot before I got started in kurimono carving, and needed something more stable under heavy horizontal chiselling. Credit: D. Campbell
Using your bench, to build your bench. This picture was taken as I was making the Atedai… with no stops and no feet I could still make the stops, cut out the sliding dovetails, and make the legs. No vise? No problem! That is the beauty of Japanese tools, for me. A heavy beam will stay put under its own weight, but legs, dowels, or similar, underneath will definitely stop it from shifting. The addition of a diagonal brace between sawhorses creates an incredibly stable working surface. Credit: D. Campbell

Miscellaneous 

As you have no doubt seen, the potential ways to use the Atedai are incredibly varied. In this section I will outline some interesting techniques and ideas that may help show you just what is possible with these benches, or at least give some food for thought.

Firstly, using low sawhorses of the same height as your Atedai is a great way to extend the length or width of the work surface, and is a great solution for things like doors or shoji frames. It can also be incredibly useful if combined with, for example, a chop saw set at the same height.

Combined with low sawhorses of the same height, you can extend the workbench surface lengthwise or sideways. A great solution when working with things like doors, or longer sections of stock. Credit: D. Campbell

Next, in a real blurring of east and west, you can put dog holes in your workbench – similarly spaced as you would on a normal workbench, for use of bench dogs, and hold fasts (Veritas make a lovely version which you can hand tighten). This can really add some versatility to your bench.

These holes will also give you an alternative to the ‘foot clamp’. By making a piece of wood with a hole drilled about ⅓ of the way in from one end, and a bolt passing through it into a dog hole (no need to attach a nut to the other end), you can create a foot-operated lever to press a workpiece into your stop, holding it very securely. The picture below shows Mr. Inomoto using this ingenious tool with his atedai

Isao Inomoto making one of his famous plane blocks using an ingenious ‘foot clamp’. A series of holes along his bench allow for different size blocks. Credit: Daiku Dojo http://www.daikudojo.org/Archive/20071028_inomoto_dai_making_seminar_day2_kiwa_kanna/ 

Conclusion

So, there you have it, a whistle stop tour of how to use an atedai. As you can see, the atedai is hugely versatile, and can offer all woodworkers, especially users of Japanese tools, a great way of working.

Low workbenches of various styles are used by a huge range of specific crafts within woodworking (as well as an equally large number of crafts outside of woodworking). I hope to have sparked some ideas that will be useful in your own work. Even if you continue using a Western bench, I hope you got a hint just what can be achieved with a couple of stops and your body…

While this way of working initially may appear quite simple, this simplicity belies the huge degree of nuance required to get the most out of it… from construction details to actual use. Often it’s not what the bench brings to you, but what you can bring to the Atedai, that determines the benefit it can provide.

You will also have seen that the benches themselves, as well as the methods of using them, are as unique as the craftsman employing them, so if something works for you, and is safe, crack on. There is no ‘one way’ to work with an Atedai, and I would love to see you at work with one of your own.

The best way to get a real sense of these benches in use is to view a range of craftspeople, including some of Japan’s “Living National Treasures,” actually using them, and so I wanted to leave a list of links for you to ‘steal’ some ideas of your own.

DC

Previous Posts in This Series

The Japanese Floor Workbench (Atedai 当て台) by Dominic Campbell – Part 1

The Japanese Floor Workbench (Atedai 当て台) by Dominic Campbell – Part 1

My workspace, and newly finished workbench. Credit: D. Campbell

The Shokunin’s art is difficult, if not impossible, to separate from his work space, his tools and his equipment. The craft is not apart from his life so much as it is a heightened detail of life.”

Toshio Odate

Foreward

Today’s article is a guest post by Mr. Dominic Campbell, a friend and deeply Beloved Customer residing in Old Blighty who, when he needed a workbench, decided to make a traditional Japanese atedai, a solution I too am very fond of, even if my knees aren’t anymore.

This is the first in a two part series about his atedai Dom was kind enough to share with us. This first part is about the design and construction of the atedai in question. The second part will be about how to use this excellent tool. Enjoy!

Stan Covington

Introduction 

I began woodworking, I guess, like a lot of the readers of this blog, with some hand-me-down western tools, and a pair of cheap, flimsy, store-bought sawhorses. A lack of space, the inclement British weather and my lack of any form of work holding made sawing and other simple tasks difficult and frustrating.

I then stumbled across a video of a Japanese craftsman working in a very similar manner, yet with far superior results… I had to know what this guy knew. While reading, practicing, and absorbing as much information as I could ( some would say falling down the Japanese woodworking rabbit hole), my work developed, and I built up my skills to a point where I felt the need for a dedicated workbench. Using Japanese tools for 95% of my work, I have found they work best as part of a system, and so decided on a Japanese floor workbench AKA an Atedai (ah/teh/dai 当て台). This kind of workbench lends itself to a very flexible workspace. It can be adapted to use standing up, and easily stored out of the way conserving space when necessary, an important part of the Japanese tradition.

Much of my own work is kurimono (刳物), or carving from solid blocks of wood, as well as a bit of sashimono casework (指物) and tategu joinery work (建具), including kumiko-zaiku (組子細工). I tried to make one bench that would work for all of these specialties, but with an emphasis on the heavy chisel work needed in kurimono. 

The first trays, called Wagatabon (我谷盆), I made with my new workbench. All carved from solid blocks of walnut. Credit: D. Campbell

After keeping Stan up to date with my progress on the workbench build, and showing him what his tools had been up to, he asked if I wanted to share my thoughts on this style of workbench.

And so, in this mini-series, I hope to show you, Gentle Reader, a method of working, and work holding that may, or may not, be of immediate practical use to you, but that is interesting, and provides some food for thought, nonetheless.

Atedai Construction

Before we look at how to use an Atedai, we first need to build one, and although the construction of the Atedai is simple at first glance, there are a few important considerations and details to keep in mind.

It must also be said here that all workbenches are as varied as the people that use them, and this is no different for the Atedai. The type of work you do, the materials you work with, the training received, how tall you are, how you intend to use it… the list is endless…will all dictate your bench’s dimensions, design details and final appearance. It is not uncommon for craftsmen to have several atedai on-hand depending on the task undertaken. In this post I will focus on just a single way to get the job done.

A craftsman caressing his atedai’s top. This picture was taken by his wife who wished he would give her as much attention. But what would she say if he beat on her with a hammer? Be careful what you wish for. (SRC)

The Work Surface

The work surface is the heart of any workbench, and it is no different here. We mostly have the same considerations too: single slab, or laminated? What species of wood? How long? How wide? How thick? What height? Will it be flat or angled? There are no right or wrong answers, within reason, and is often a case, the final selection will depend on what you can get hold of, what you like, and the type of work that you do (you can start to see why craftsmen often have a number of benches in their workshops – they are easy enough to make, and store easily out of the way, taking little space, so why not?).

My own bench top is a 57″ x 17″ x 3.5″ sycamore slab (and 7″ high with the legs in). This is quite long for the work I do, but it gives the bench good weight/inertia, and is useful for the occasional long beam I have to work. It was not, however, easy to get flat, nor is it easy to keep dead flat along its entire length and width. You pays your money and you takes your chances…

An old beechwood atedai (SRC)
Four laminated atedai in a woodworking classroom stacked off to the side. Notice they are stacked on their left edges and not their right. This is because the right edge is used for shooting and must be kept clean and free of grit. (SRC)

A Few Observations

There are a number of possible answers to the questions posed in the previous section, and so I thought it would be useful to briefly explain my thoughts behind the selection and preparation of my work surface in order to give some insight into the kinds of questions you should be thinking of.

With regard to construction, you have to weigh the pros and cons of each approach, and make a decision that works for you. A laminated top will tend to be a bit more stable, whereas a solid top could be liable to warping a bit more. A solid slab is a bit more traditional, can be made to move a bit less through certain techniques (as we’ll see below), and is quick and easy to put together – i.e. you buy it, and apart from surface prep, the top is basically done. That said, big slabs can be harder to find (depending on where you are), and can be expensive. I actually found it easier to find a slab, than it was to find smaller stock of the same woods…. most lumber yards near me won’t give small orders the time of day… it was either construction pine, or a big hardwood slab. I hope you have better options!

In terms of wood choice, most woods commonly used to make workbenches will work fine. Too soft and the atedai will be easily damaged, but too hard and the atedai may damage your work (especially if using softer woods), and become slippery. Woods with contrasting hardness between winter/summer growth like douglas fir can work, but problems can arise especially if you shoot a lot on the surface, as the winter wood and summer wood can wear down at different rates leaving ridges. I went with Sycamore (Acer pseudoplatanus – actually a kind of maple) as it has a fine grain, is medium hardness, and I could get hold of it in the right dimensions for less than £100… all important considerations!

To make sure my top was as acclimatized as possible, I left it for about 5-6 months in the workshop where it will be used (it was air dry when I bought it, but I don’t know for how long). My shop is an unheated 1 car garage, and not climate controlled (I use a small dehumidifier, however), so I expect some movement. That said, I wanted to give it the best chance of settling in before I started flattening the top, and doing the joinery for the stops and legs.

When I brought the slab home it had quite a bit of cup and twist – one potential downside of using big slabs – and it took some hard yards to make it flat and twist free. I left the underside untouched as much as possible – to retain as much weight as I could in the bench – planing only where the legs would go, plus a bit on either side. Preparing a big slab, unless you have an industrial sized planer, is a hand tool job, so prepare yourself for a work out.

The sides of my bench are 90° to the top, with special attention placed on the right hand side when sitting at the working end. This is traditional with atedai because the user indexes a plane vertically against the right hand edge of the top to quickly shoot the edge of boards to 90° , although I prefer to use shooting jigs to help when 100% precision is needed. You can also attach a length of wood to the right hand edge to form a support ledge for the plane when shooting.

As you can see in the pictures, this slab has a few knots scattered about, which I stabilized with CA glue, and planed flush. This has worked well so far, but if the knots come loose in the future, I will cut them out and patch them.

With regard to dimensions, the general rule of thumb is that if you work wider boards you tend to need a wider bench (although you can up to a point plane wide boards on the narrow bench, it can be hard to use the bench as a reference surface to check for twist). However, too wide is harder to keep flat, is heavy, and is more expensive. 

Too short a bench makes it harder, if not impossible, to plane longer stock. But again, too long is heavy, expensive, and harder to keep flat (can you see a trend here?). It is also impractical, unless you are Stretch Armstrong, as you can only plane as far as you can reach while sitting or kneeling. That said, you can (as you will see in Part 2) put a floor bench on saw horses (or your normal workbench) to use standing up to increase your reach, in which case a longer bench can help cover long stock prep too.

A zabuton cushion for use while sitting on the floor while using the atedai (SRC)

The final question regarding dimensions is total height, a combination of top thickness plus the legs. Most people use an atedai while sitting on a zabuton cushion placed on the floor like the one shown in the photo above. In this case, the bench top should be low enough to hit your knee so you can stop it from sliding, but high enough that your plane will not hit your knee (ouch!) when planing or shooting down the middle of the stops. Somewhere between 4-7 inches high normally works well, with a slab thickness of between 2-4+ inches, YMMV. If in doubt, go higher – you can always reduce the height slightly later down the road. And zabutons tend to become thinner with use.

Another consideration is perhaps unique to the Japanese atedai, namely whether or not to build the top with a slope. Some craftsmen prefer the bench to slope down towards the end they sit at for ease of planing, but I prefer a flat surface. It’s a better all-rounder, and it’s easy enough to prop up the far end temporarily if desired.

To slow down any movement, I sealed all end grain surfaces (using Osmo End Grain sealer) on the completed workbench (top, legs, and stops). All of this combined (plus dovetailing the legs, as explained below) has worked well to stabilize the top, and movement has been minimal, although it’s always worth checking before any fine joinery task… little and often is a good idea for keeping a bench flat. 

The end grain sealing is all the finish I have applied to this bench. I left the top with the planed surface in order to keep it from becoming too slick. As I don’t use a lot of glue or finishes in my work, I didn’t apply anything else to the surface, but a light coat of oil can help things from sticking too much if needed.

The Legs

Now back to the construction of the atedai, we come to the legs, or battens, which should be thick and solid – in my case 4×4 inch sycamore attached to the underside of the top with sliding dovetails.

You can simply toe-nail, or similar, the legs in place if you wish, but the sliding dovetail helps to keep the board flat and is, IMHO, a much more elegant, long term, solution. It is not uncommon in Japan for these benches to be passed down from master to apprentice, so I built mine too with longevity in mind. Sliding dovetails can also help knock the bench down for storage or transport, if that is something that you will need.

This bench was made entirely with hand tools. Notice the partially-completed double-tapered sliding dovetail that will receive one leg. This joint is hard to achieve using machines. Four Atsunomi chisels, a Kosaburo gennou, and the indispensable oilpot are taking a break in companionable silence and waiting for the kettle to boil. Credit: D. Campbell (tools by C&S Tools)

After talking to Stan, I went with a double tapered sliding dovetail, which helps the legs fit extremely tightly (while also being much easier to slide in place), and helps resist humidity fluctuations, bangs and vibrations better than a standard tapered sliding dovetail – all important advantages for a workbench. 

The double taper in this case refers to a taper not just in the width of the dovetail (as is fairly common) but also in the height of the groove along its length, with the leg tapered to match. This connection can be achieved in any number of ways, in my case with plane and kotenomi. The tapers on my bench were around 1cm in width, across the board, and 0.5cm in height – this still made for a pretty tight fit.

My legs right now are just a bit proud of the edge of the top while it settles in, so I can knock them in further later if needed. Their slight projection doesn’t interfere with shooting with a top that is 3+ inches thick however, so they aren’t causing any headaches being a little proud…

The Kote Nomi, or Trowel Chisel, excels at this work and is a joy to use. Credit: D. Campbell

As a final touch on the legs, and to give the bench the most stable footing possible, it is wise to relieve the middle of the legs slightly – just enough to keep it clear of the floor. Also, some thin rubber, cork, or in my case, part of an old chisel roll, help to prevent the bench from sliding around. You don’t want to use anything too thick however, as that will absorb too much shock, reducing the efficiency of your hammer blows when chiseling.

A view of the underside of the atedai showing one leg tightly inserted in a self-locking double-tapered dovetail. The legs are slightly relieved in the centre to prevent high-centreing on uneven surfaces. Non-slip feet are optional – just don’t make them too thick. You can see where I have left the underside rough-sawn to retain as much weight as possible. Credit: D. Campbell

The Stop(s)

The work you do will determine what kind of stops you need. Sashimono-shi tend to use much thinner stops, while those using the bench for kurimono, or hollowing work, will often (but not always) use more substantial stops to stand up to the forces involved, often with just one stop across the entire width of the board. Again, it’s horses for courses.

Back then, to our good old friend the sliding dovetail. In my case for the stops, I used a regular stopped sliding dovetail. I didn’t taper the stops at all, as I wanted to make sure they stay in place firmly – a sideways knock on a tapered stop will send it flying too easily for my liking.

Completed stops. You will get plenty of sliding dovetail practice while making an Atedai. Credit: D. Campbell

My stops are quite substantial, much bigger than I have seen sashimono-shi use, but stop short of a full width stop, in order to leave room for morticing longer stock (see part 2, coming soon, for the venerable bum clamp), as well as a gap for shooting. If you decide to make your own atedai, you will need to consider what work you will use it for, and plan your stops accordingly.

One useful feature of the stops is that being dovetailed, you can make several and interchange them, or remove them completely, depending on what you are doing. These benches really are incredibly versatile, and are completely custom to the work you do – a joy to use.

Summary

The finished Atedai, ready for action. Credit: D. Campbell

And there you have it. Four sliding dovetails cut into a slab of wood to receive two short legs and two stops and you have yourself a workbench that is quickly ready to go to work but easily stored away in a few seconds when not needed.

I hope, in this post, to have given you some insight into how to build an atedai workbench for yourself, and some of the considerations you must think about if you do. They are simple benches, but there are a few important considerations to think about before you decide to make one. If you have any questions, just leave a comment below, and Stan or I will do our best to help.

In Part 2 of this mini-series I will show you how you can actually go about using such a workbench, some further customizations that one can make, and some examples from other craftsmen to help inspire you – I hope you’ll join us. 

Yours in wood,

Dominic Campbell, Kent, UK

Other Posts in This Series

The Japanese Floor Workbench (Atedai 当て台) by Dominic Campbell – Part 2