Cutting a Maple Burl Cap into Blocks - Step by Step

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This thread shows how I cut up a big maple burl cap into knife handle blocks. The burl I am using in this thread is a maple burl cap that was harvested in the fall of 2008.

You probably noticed that the exterior is gray instead of a golden color. That is because I left this cap outside to season instead of inside our burl barn. Most of our burl caps are pressure washed and stored inside a barn while they dry. That will maintain a clean golden color on the inside and outside of the burl. I like to take some of the burl caps and leave them outside to season and weather naturally. Under one of the trees here I place the burl cap with the cut surface against the ground and just leave it there for a year or so. By doing this the burl absorbs some of the minerals from the ground as well as bacterias from the rain run off. In the end the burl will have more interesting coloring than the plain white / gold coloring. Some I will leave for years and allow them to spalt. We have so much wood here that we can experiment with. If I ruin a piece it becomes firewood.

This burl cap is about 2 feet by 3 feet and about 7 inches thick at the dome of the cap. It was harvested from the side of the trunk. Maple burls form as a bulge on the side of the trunk, or as a root burl, like a big onion at ground level. Burls like the one in this thread tend to have more compact figure than the larger underground burls.

This is a photo of the burl cap before I started cutting.
m001.jpg
 
My first step was to decide where to make my first cut. I wanted my cuts to follow the direction of the tree trunk that the cap was cut off of. With a piece of masking tape I marked where the cap began to taper away from the crown of the burl cap. Since I am making the first cut freehand, the tape gave me a guide to keep from making too crooked of a cut.

mb001.jpg


This cap was too big for my 18 inch grizzly bandsaw (don't ask how I know) so I cut it on my boss's bandsaw. He uses an old "Butcher Boy" meat cutters bandsaw. It's a monster that will cut just about anything you can fit on it's table.

This shows the first cut.
mb002.jpg
 
Next I took the piece with the larger, flatter dome area. I marked it with tape for the next cuts.

mb003.jpg


Next I trimmed away 2 edges to give the piece more of a block like shape.

mb004.jpg


The reason I cut this piece the way I did was so in the end I could cut blocks with the face surfaces parallel to the outer surface of the burl.
 
Taking the trimmed block, the next step is to cut it into slabs. Since I wanted the block faces to be parallel to the outer surface of the cap I cut the slabs 2"+ thick.

mb005.jpg


With one of the slabs that was cut from the block I drew a line parallel to the outer surface.

mb006.jpg


That cut is to make the straight edge I used to cut the strips from the slab. These strips were cut about 1&1/4" thick.

mb007.jpg
 
After that I cut the strips into blocks.

mb008.jpg


Next a quick belt sanding.

mb009.jpg


And finally a block dampened to show the figure next to a piece of the outer portion of the burl. You can see the figure mirrors the outer surface of the burl when cut this way.

mb010.jpg
 
All kinds of neat! Out of curiosity, have you ever taken a fairly flat piece of the outer portion of the cap and just grind down the outside until you have solid wood in an area the size of a set of knife scales? I wonder what kind of figure you'd get there?

--nathan
 
All kinds of neat! Out of curiosity, have you ever taken a fairly flat piece of the outer portion of the cap and just grind down the outside until you have solid wood in an area the size of a set of knife scales? I wonder what kind of figure you'd get there?

--nathan
Probably pretty good. I'll go try a piece right now.

003.jpg


If some was left natural surface and some ground flat, it might work. Kind of like what you do with popcorn stag.
 
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It was worth the wait Mark! I've only been asking like, since forever. :p It's great you make the time to share these how-to threads with us. We REALLY appreciate it. THANKS!!!
 
Probably pretty good. I'll go try a piece right now.

003.jpg


If some was left natural surface and some ground flat, it might work. Kind of like what you do with popcorn stag.

Uhh... what do you do with your scraps? :p

(Please don't say burn them. Please don't say burn them.)
 
A few of you asked me when some of this burl would be available.

Thursday 12/10 I will be listing a bunch of blocks that I cut from this burl. Probably around noon my time.

Uhh... what do you do with your scraps?
(Please don't say burn them. Please don't say burn them.)
__________________
--Mike Jones


I will see if I can gather up a bunch of cut offs that would be good for spacers and put together some sort of give away.
 
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Is it me, or does that burl cap look absolutely disgusting? Like a huge, dry, crusty colony of warts! Am I the crazy one here? Sorry...
 
Is it me, or does that burl cap look absolutely disgusting? Like a huge, dry, crusty colony of warts! Am I the crazy one here? Sorry...

Actually it is more like a colony of warts with sharp pokery things on the ends. Felt like I was wrestling with a 50 pound porcupine. I have to agree with you as to the look, not sure yet if you are crazy or not though.
 
A few of you asked me when some of this burl would be available.

Thursday 12/10 I will be listing a bunch of blocks that I cut from this burl. Probably around noon my time.

Uhh... what do you do with your scraps?
(Please don't say burn them. Please don't say burn them.)
__________________
--Mike Jones


I will see if I can gather up a bunch of cut offs that would be good for spacers and put together some sort of give away.


I had a feeling you were going to be doing that....Guess I'll wait a day or so before I pay you for the other stuff. In case I see something I like, I dislike you for getting me hooked on this stuff :p
 
question: how do you determine the long axis of the work (like a knife handle) from a lump of burl if there's no grain?
 
Thursday 12/10 I will be listing a bunch of blocks that I cut from this burl. Probably around noon my time.

Can anyone say FEEDING FRENZY?

Let's see, that will be at 10AM Hawaii time. Darn I'm teaching a jewelry making class to 11th graders then!
 
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