Sizing the Hat
Wood
turned Hats are Conversational Sculptured Wood Hats to be Worn or
Displayed. The process of transforming a piece of rescued wood (usually
18"- 20" in diameter & 20" in length, weighing around 200 pounds) to
a spectacular sculpture weighing less than 12 ounces. Using a curvex
flexible ruler, I measure the head to determine the exact shape of your
head. A wooden hat must be carefully configured individually for each
customer.
Selecting the Wood
The
hats are fashioned from native woods, Pecan, Oak, Maple are some of the
them, I spend a great deal of time appraising downed or felled trees to
find the perfect piece. The wood must be green and free of cracks where
the bream will be. The best wood for a hat is from a tree that doesn’t
know it is on the ground. The beauty of the grain, the inclusion of
bark, the imperfections of fungal invasion (spalting), the work of the
Ambrosia beetle, and the burling of the wood all contribute to the
magnificence of the art.
Preparing the Blank
Using
a chain saw, I will cut the approximate size of the hat and also make
the blank as round as possible prior to placing it on the lathe. Because
balancing of the wood is of primary importance, proper preparation of
the blank reduces turning time as well as wear and tear on the lathe and
tools.
Rounding the Blank
The
blank is placed on the lathe and carefully centered for weight. With
the turning speed set at a moderate pace, the initial process of outer
shaping begins. Shavings vigorously fly through the air and moisture
being released from the wet wood is released. Care must be taken at this
point to obtain a perfectly rounded blank with no torn grain, splits or
checks.
Shaping of the Hat / Turning by Light
The type of hat to be turned determines the outer shape of the blank.
With
the basic outer shape obtained, the hollowing process is begun. Wet
wood is translucent, so a light is stationed behind the brim to give me a
reference and establish a uniform thickness across the hat. Beginning
at the outside of the brim and working toward the center of the hat
slowly and careful removal of the wood is accomplished. During this
process, I constantly measure the hat’s thickness with a final goal of
3/32 of an inch. Great care must be taken at this point due to the
living nature of the wood which tends to move, depending upon the
character of the grain, the direction of the cut, the type of wood
selected and the amount of moisture contained in the wet wood as the
piece dries.
Because
of the shape the thickness of the entire hat cannot solely be
determined by mechanical means, I must ascertain by feel, sound of the
tools as they cut the wood, and by sight, the appropriate thickness of
the hat. By placing a low-wattage bulb inside the crown of the hat and
working in near-darkness, the turner uses light, sound and traditional
measuring devices to guide him as he removes as much of the waste as is
‘right’ for that individual piece of wood. The light generated by the
bulb causes the hat crown initially to appear a glowing red color. This
gradually become brighter as the hat approaches the correct thickness.
Sanding
Sanding
is begun while the hat is still on the lathe. This allows the hat to
rotate and the sanding to be even. I begin with a coarseness of #120
grit sandpaper and continue the mechanical sanding until a grit of #320
smooths the hat to a fine natural finish.
Burnishing the Hat-Band
The
hat-band is approximately 1/32-inch thicker than the crown. This gives
the appearance of an ‘attached’ hat-band. A contrasting colored piece of
wood is used to apply the hat-band color (generally uses Ebony, Padauk,
or Rosewood, depending upon the color desired.) The complementing wood
is burnished on the raised hat-band and the color is miraculously
absorbed by the hat.
Bending and Final Shaping
Immediately
after the hat has been turned and sanded it is placed in a custom-made
jig so that the bending and final shaping may begin. The brim is
stressed and gentle side pressure moves the hat from round (as it came
off the lathe) to oval (the shape of the customer's head.) Heat lamps
are applied to dry the wood in an even manner. Rubber bands are used to
assist in the bending and shaping.
Final Hand Sanding
After
approximately 3-5 days of bending, shaping, drying, and constant
around-the-clock attention, the hat is hand-sanded removing all
imperfections and tool marks. This tedious but necessary work achieves a
magnificent finish for the work of art.
Applying the Finish
Approximately
5 coats of Wipe on Polly is applied in a controlled environment, over a
period of several days, depending upon the type of wood. Each coat
brings out the natural beauty of the wood.