UPDATED Drying burl for handle material - the long way

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Every once in a while someone will make a post asking how to dry some fresh cut burl fast so they can use it for knife handle material. There is usually talk about using a microwave or an oven which usually just ruins a good piece of wood faster.

Several years ago I was talking to Chuck Bybee of Alpha Knife Supply about drying burl to be used as knife handle material.
The subject of the difficulty in drying Madrone Burl came up and Chuck said I should try wrapping the wood in plastic pallet wrap and leaving that to sit for awhile before actively taking steps to dry the wood. So I decided to give it a try. I wrapped a few large chunks and put them into a dark storage area. About a year ago I unwrapped and cut them up after having forgotten them for about 3 or 4 years. Now I just pulled the last chunk out of storage. I think it has been hidden away wrapped in plastic for about 5 years. I really don't think Chuck intended that I wait this long before unwrapping.

When I pulled off the plastic the wood was dark, wet and slimy. GOOD!
I split the chunk so I would have a manageable size to cut on the bandsaw.
The wood is currently over 35% moisture content.
Most of the color inside has changed from a light orange to a milk chocolate brown color.
I have cut it all into 1&1/4" thick slabs and will let them air dry in a dark area of the shop for a few days so some of the surface moisture will go away.
After that I will wrap the slabs in paper bags and put them into the drying room for about a week. This allows the moisture to redistribute so the wood won't move as much.
Finally I will cut the slabs into blocks and dry them on a rack in the drying room with forced air (whole house furnace fan) and a dehumidifier.
If all goes well the moisture content will be under 10% in about 4 or 5 weeks. (last ones took 4 weeks in the drying room)
Then off to K&G for stabilizing.

Here are some photos of the chunk I cut up. When dry the color will be kind of gray/brown.

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Many types of wood would have turned to mush by now if I had treated them like this. But with Madrone Burl, this way works with very little waste caused by cracking and movement.
A point I would like to make is that there is no single way to dry all types of wood. If you do everything the same way, some will turn out good and some will get ruined. So you have to experiment and find out what works best for what you have.
With Madrone burl the wood has tiny pores that you can barely see. That makes it so the wood takes a super nice, smooth finish. But it is also what makes the wood so difficult to dry using normal methods.
 
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NICE!! I love the look of burl. That madrone burl has some really nice figuring.

Do you know how soft it is compared to box elder burl? Or just how soft would you describe it in general.
What type of stabilizer is going to be used?
 
Much harder than box elder. I would probably compare it to American Black Walnut. Maybe a bit harder.
I will be sending it to K&G for stabilizing.
 
let me know how it works...I have tried many ways...knife handle is Pacific madrone burl and slabs are super dense old growth redwood

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I posted for years under SCOPAC495 selling to game call makers...I don't do that anymore, just collect wood for my own uses. I have a dehumidifier heated room that the wood went to after 1 year air dry...it worked well if ends were anchor sealed.
 
Mold makes amazing stain patterns and colors.

This wasn't just mold. It was wet, slimy, sticky, moldy goo. It looked like the slime in the bottom of a dumpster but it didn't smell bad.
Here are a couple photos of the chunk coming out of the plastic.
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Yep. I hate goo, but mold loves it. Dries up fast on plus side :) You might have a bit of blue stain going on, but spores would have been on the wood before plastic wrapping.
 
Maybe you'll know Larry.
I am guessing that during the time wrapped, holding in the moisture is causing the wood fibers to break down, making it so when the madrone dries it doesn't tear itself apart. Not sure if I am making sense but I would like to hear any input you might have.
 
I have a small 48"X48" utility trailer that I place 6-8" thick slices of trunk sections with spalt in and let dry....sometimes 1000 pounds of them. I set them on edge and space them with pieces of 2X4, cover with a tarp, and let dry for as long as it takes....and it can take a long time. Slow drying in oversize sections reduces the checks a lot. In the beginning they get covered with slimy mold as the moisture wicks out. Then they dry nicely with even better spalt. It eliminates termites and rot that happen with on-ground or low pallet storage. When they get down to 15% or so moisture content, I cut up into oversize blocks or large slabs and dry "jumble stacked" in milk crates until down to 7-10% moisture content. At this point, they are ready to trim into blocks for stabilizing. I get a few boxes of super looking handles and a big pile of firewood, but the stuff I keep is superb.

TIPS:
Milk crates are great for storing and drying wood, as they allow air circulation and are easy to peek in and look at the wood. They stack stable 6 feet high in a very small footprint. They load in the back of a van or truck great, too.

Tie a string tag shipping label on each crate with wood type, dates harvested/slabbed/blocked/etc., and any notes on the wood. You might remember everything about that wood right now, but in 2017 when it is ready to use, that isn't a sure bet!

Labeling wood when you make handle blocks is the only way to assure mix-ups won't happen. Wood boxes get dumped out and mixed up, wood changes color in time, memory fades, etc. Mark every block or scales with an ID #.
Make a log book and put in the numbers, species, source, dates, special notes, etc. Start with #1 and just go to 99, Then re-start with A1 and go to A99, B1.... etc. This will take care of 2,673 blocks of wood. White metal marker pens are the best to mark with. Mark the end of the block to make reading easy when stacked. Another method is to use a 45 watt soldering iron with a chisel tip ( or a wood burning iron) and mark the end. If you send wood out to be stabilized, also mark your initials when labeling.
..................Sub Tip: You can also record the block number in you knife making log book ( another good idea) and even on your knife certificates. That way you can easily identify the wood with a glance in the log book. I can't tell you how many times I have asked what wood a knife handle was made in and the maker's response was, "Umm, it was either X, Y, or Z wood, but I forgot." Once shaped, sanded, buffed, etc. it can be very hard to ID many woods clearly.
 
Back to the slow drying of the Madrone Burl
I got busy and the slabs were set aside in a dark part of the shop and forgotten. I was going to wrap them in paper grocery bags but they were stood on end instead. This way they had airflow around them for about a week. After that some of the moisture had evened out so I guessed it was safe to put them in the drying room on a bread rack with the fan and dehumidifier going.
This morning they were looking pretty good so I pulled them out for a closer look. Using a pin type moisture meter it read 10 to 12% moisture content. NO WAY THAT IS CORRECT. That was just the outer portion of the wood.
They felt a lot lighter in weight so I decided to thickness sand them and do a bit of trimming for a better look at how they were coming along. There was very little movement (warpage or cupping) and no cracking. That alone is a minor miracle with Madrone burl.

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Drum sanded at 36 grit I can see if there are drying flaws and get a better look at the figure and grain patterns before cutting blocks.
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Since the drying process often produces warping and checking, the lumber is usually steamed for 6-8 hours and then cooled rapidly before the drying process starts. Steaming the wood diminishes the possibility of cellular collapse in the middle of the boards and it also proved for a more consistent color throughout the wood. It is critically important to monitor Madrones moisture content (MC). ...From www.Wagnermeters.com
Did you steam yours ?? Apple used to be put into a pond for a year, have you tried that with madrone ? Just trying to learn !
 
I didn't steam this wood. It was just left wrapped in plastic pallet wrap for several years.

One of the pieces had a bit of checking starting at one end. So I kept trimming until I got past any checking and then I sealed the end grain. Another piece that I cut in half showed the inside was still not dry. So I left a bunch of the pieces long and put them back on the rack in the drying room to finish drying. When I think they are ready I can still cut a long piece in half to check how dry it is inside. Once they are at about 8% moisture content inside and out, then I can send them in to be stabilized.

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Here I found an old photo of when this wood was fresh cut in January of 2010.
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It has been a while but the Madrone Burl finished drying and was sent to the stabilizers. It came back today. Now I just need to get the blocks all cleaned up so they can go into the store.
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