Again, no power tools allowed.

[formariz 12,200]

Started another one a little while ago. Again all entirely done without using any power tools . I am continually asked why . Sometimes it sounds like people think I like to torture myself but it’s much deeper than that. Besides the cultural aspect of it, if I don’t use what was handed to me the way it was handed, it will be lost first by me and consequently by others not having the opportunity to see what is possible without relying on machinery . On a deeper level I like to feel what they felt and to decipher not only the why but also the how of the parts they didn’t have the chance to teach me. Many of those are not even possible with power tools. When that happens they are many times outright emotional moments of accomplishment unequaled by any other time. With your indulgence like before I’ll continue posting its progress as I go along. 

It all starts with some ideas and a drawing. Always with strong influences from the ones before modified to reflect my own ideas but still respecting and acknowledging the originals. 

 

The material comes next. Carefully selected and guarded for many years waiting for this moment. Ash the traditional species used for this due to its strength and flexibility under load or stress. As is from the mill from now on no power tools will touch it. 

 

Flattened , straightened , unwound , and reduced into a certain thickness to start the process. 

 

a template is made of drawing to choose the best area of plank to use and to layout all the cutouts. Important to choose area of plank carefully since much of end product may have very thin or delicate areas which will be prone to cracking if not done so. 

 

[Achto 29,863]

I'm in.

[Ed Kennell 43,106]

44 minutes ago, Achto said:

I'm in.

    Yes Sir X2

[ri702bill 10,074]

Sad to think that the younger generation's idea of "Fine Crafted Furniture" is IKEA.....

[ebinmaine 74,582]

2 hours ago, formariz said:

With your indulgence like before I’ll continue posting its progress as I go along. 

 

Absolutely looking forward to seeing the entire project. 

I share these occasionally with The BBT aka Trina aka I'll try anything once. 

 

I may not respond or even "like" all the posts but rest assured you've got my attention....

 

[adsm08 3,631]

The skill and attention it takes to do something like this always amazes me.

[mrc 1,000]

craftsmanship like yours is virtually a lost art these days.  always very impressive!

[8ntruck 8,156]

I love your philosophy on this.

 

I hope that you are fortunate enough that you might be able to pass your skills and knowledge on to younger generations.

[953 nut 62,189]

Cas, it is so good to have you back demonstrating the craftsmanship the rest of us can never match but do respect. Looking forward to every post.  

[rjg854 12,515]

I bet it's even therapeutic for you to do this, Caz. You can do it at you're own speed and when you want to. I can see where it would be relaxing and a way to experience the past.

[kpinnc 15,718]

@formariz

 

Your previous work has been incredible! You have skills and patience that I can't fathom. 

 

My shop would have tools stuck in the ceiling from one end to the other where I ruined something and threw the tools and stomped out! 

[formariz 12,200]

Once the plank is marked on one face one proceeds to drill through the parts that will be removed as much as possible minimizing labor in clearing them later. This is one of the most crucial operations since one has to drill it perfectly perpendicular to face of board. Opposite side will have exactly the same carved design and any small deviation in the drilling process can be catastrophic. Contrary to in the past I no longer do that on top of my bench therefor not being able to have a square standing next to the auger for reference. I started drilling it on the actual carving table which is at an angle. The previous way was taking a toll on my back from hours of leaning over bench. At the carving table I stand with a straight back all the time. This however proved to be quite difficult in maintaining auger perpendicular to board since I also could not have a square next to it as reference. For that I devised this articulated  jig which will guide auger perfectly perpendicular to board and can be adjusted and moved readily through out it without being removed each time. It will work for any size auger since it guides the side of auger within the "V". One merely "taps" it to put the screw tip of auger on desired hole's centers. I have been improving it over time now adding a bronze angle as a wear strip.Sides of auger were cutting through it quickly.This has proved to work really well specially on my back.

 

Shaded areas to be removed

 

Drilling of shaded areas

 

 

 New way using jig to stay perpendicular to board at tilted table

 

 

Jig slides and articulates through entire board

 

 

Jig with bronze wear guides.

 

Old way

 

 

Edited Tuesday at 05:00 PM by formariz

[formariz 12,200]

19 hours ago, rjg854 said:

I bet it's even therapeutic for you to do this, Caz. You can do it at you're own speed and when you want to. I can see where it would be relaxing and a way to experience the past.

Extremely therapeutic. My natural way of dealing with stress or worry has always been to work . It keeps me calm and grounded. This has also always been my life’s passion so I probably spend spend more time here than anywhere else combined. Sometimes I just hang out sitting on my favorite chair chair thinking, reading or just looking at things. Sometimes sipping a little expresso and Port like today😸.

Edited Tuesday at 08:29 PM by formariz

[ebinmaine 74,582]

1 minute ago, formariz said:

Extremely therapeutic. My natural way of dealing with stress or worry has always been to work

 

Agreed. Understood. 

 

Some folks sit to "relax". I need to move about...

[formariz 12,200]

Once marked one then proceeds to drill through those parts with the appropriate size auger but staying a little away from the line. To break the monotony of the drilling sometimes I start on actually chiseling out those areas. Drilling does not actually goes through the board but stops automatically when auger’s screw tip emerges on opposite side and stops pulling. 
when board is planed on other side it will reveal all the holes. Not shown on these photos but board is blocked up from table. 
 

 

 

[wallfish 18,627]

Thank you for sharing the process and your craftsmanship with us

[formariz 12,200]

Next comes the task of going through all piercings. Tedious work still staying away from the lines . Real tight or small areas require extreme patience and sometimes customized tools. Many outwardly pointed areas are also fragile at this point. Also important to stay perpendicular to face of board and not dig in through board thickness.
 

 

 

[formariz 12,200]

Having rough cleared most of openings with the exception of some very small ones it is time now to add the bottom pieces which complete bottom of yoke. These are made from pieces of same board. The reason for these pieces are twofold. First most boards are not wide enough to make it out of one piece. Depending on type of yoke, would have to be a minimum of 24” wide. However despite of being nice having it in one piece structurally it is a mistake. With the cutout for the animal’s neck the grain in those pieces is short and it is almost inevitable that they will break. A lot of pressure is put on those areas when in use. 
 

Pieces are mortised into yoke’s body about 3 to 4 inches deep . Mortise is always done first. 

 

 Part of yoke’s body where the shoulders meet are not always flat. This part is many times the live edge of board and it is utilized in that manner by introducing another bevel on the other side. Most opted to flatten or cut this part because it makes fitting shoulders extremely difficult. 

 

 

 Shoulders are scribed to fit. This is a lengthy process . Perfection is a must for strength since nothing is glued. It’s all friction fit. 

 

 

 Tenons and shoulders need to fit perfectly. I dry these parts in the oven prior to working on them. This way they are dryer than wood in mortises. When that part eventually dries and shrinks it will get tighter around tenon. If everything is done correctly they will be nearly impossible to to remove without breaking something. 

 

 

 The fitting process is entirely done with a paring chisel a highly specialized precise tool. Leaving these parts oversize until the end is necessary as it is the only way to remove them at this point while fitting shoulders by tapping on the end of extra thickness

 

 

 

Along with added pieces, yoke body is also only cut to shape once this and all penetrations are done to ensure no cracks occur from the mallet and chisel work.

 

Edited Saturday at 05:49 PM by formariz

[formariz 12,200]

Process of using a paring chisel for fitting tenons on link below

 

 

[Ed Kennell 43,106]

Cas, I'm worn out just reading about all the effort you put into these projects.    You are my Super Star.    

[formariz 12,200]

On 11/6/2025 at 5:31 PM, wallfish said:

Thank you for sharing the process and your craftsmanship with us

Thank you John and everyone else for your interest . 

[formariz 12,200]

1 hour ago, Ed Kennell said:

Cas, I'm worn out just reading about all the effort you put into these projects.    You are my Super Star.    

 Thank you Ed. Looks like effort but in reality it’s not. When doing what one loves it comes easy . I just get lost in it oblivious to anything else.