Woodchuckery Experiment

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Jan 26, 2002
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OK, long, tediously detailed and in three parts:

1) Comments on Bura 26 oz 20" sirupati PGA (Had to get it, cheapest way to own one by him, so I can brag that it was made by the Royal Kami, and seemed the most useful size after I got a 36 oz 25")
2) My prior experience with Murphy's "Multiuse" formula soap.
3) A succesful (so far! only one day) expriment with Murphy's "Original" formula soap on the 20" sirupati. The procedure described here may be closer to what many are doing than 2).

1) The knife: "Rust at tip" has been ground off, and it was only on convex bevel. Sharpening will fix that, and its pretty well sharpened already. Otherwise the khuk is pretty much flawless, and as I suspected, an ideal size for me to use. Handle is one of the browner pieces of saatisal, and has some of the gold, but it's mostly dispersed, not in dramtic streaks. Karda is the best I've seen, very dramatic grain and it's all sapwood, edge near handle very well ground back, (1st I've gotten like this, except for YCS kardas) and it is an amazingly graceful and well-proportioned miniature of the large blade. Chakma equally finely proportioned and also has dramatic grain and color, but here the grain all runs lenghtwise, not in V's or chevrons like on the karda. Very thin where it joins the blade, and a lot of rouge/wax with a little wood showing through. Bit of a burl right there, which is why the rest of the handle has such great grain and color. More on that later. I now understand why Uncle says "Karda and chakma like only Bura does them."

EDIT to 1): Forgot to mention that the actual edge of the otherwise absoultely perfect karda has a little curve to it, but the spine has much less. And the tang and/or the handle hole is very slightly mis-aligned. Pretty picky stuff, I know. On the edge, most, if not all will stone out, I think. Still the prettiest karda I have. And the scabbard by the village sarki is the best I've seen so far. Stunning bargain.

2) "Multiuse" formula: Up to now, I've only used the Murphy's "Multiuse" forumla, which is as thin or thinner than water, and comes with a sprayer top. It rapidly soaks into the wood, leaving a dry-looking surface. but some tung oil repairs that. You can scrub out dry flecks of rouge with a toothbrush or soft, fine wire brush if you keep scrubbing after it drys. This can pretty much remove all the rouge, but can enlarge the grain, making filling a tedious proposition--so far the lighter, gold colored handles with lots of sapwood are the worst in this regard. But you do get a very light, gold color. But it can be hard to fill without getting dull, dark grey fill. I've resanded things back to nearly bare wood a couple of additional times to try to minimize this. Wal's "eggshell" description is nearly applicable on some areas of a couple of handles. But this scrubbing could be could be good for the oily "other saatisal" so some tung oil might be able to soak in.

3) The experiment: After reading about Wal's experience with complete removal of rouge/wax by hoof-dressing, I though that I might have been doing something similar, but not so extreme with the "multiuse" formula. I thought I'd try instead to retain all the grain fill by wax/rouge already there, and if possible, extend it. I could always sand more, or even scrub it out later I didn't like the result. How to do this?? Maybe by heavy power buffing with the hope that the wax might soften and get spread around more. Lacking a power buffer, I tried something else. I applied a thin coat of the thick, "original" Murphy's soap (just like I would apply tung oil) and started sanding with used 220 grit paper or new 320 grit paper. As I expected, the rouge/wax came off, and clogged up the paper. But it wasn't long before the wood surface was present nearly everywhere, and with new paper I was producing dry sawdust. The thick Murphy's didn't soak in that deep. I repeated the thin layer of soap and the wood went translucent like with oil and I could see where I wanted to sand down more. Again, I intially plugged up the paper and removed a lot more rouge. But after the dry sawdust was coming off, and the paper got a little worn the wood started to develop a nice polish. As I had suspected the burl area on the chakma did have a little bit filled by the rouge/wax and I wanted to retain that if possible instead of exposing duller-looking Himalayan epoxy, or doing a big fill job. I went to 400 grit, and put on a pretty good polish and the lighter-looking areas of fill showed that only fairly fine grain was getting now filled. I then repeated the whole deal once more, now going from used 320 grit to romove the paper-clogging stuff, then going to to 600 grit, and even the back of the paper for a final polish. This entire procedure was pretty quick, since the wood was a little softened by the soap. Since I sanded enough to get totally dry sawdust, I think there's little soap left, except in the fill areas. Very nice fine fill of rouge accentuates the remaining grain. I put on a (single, so far) layer of tung oil and the karda and chakma already look really great. The khuk handle could maybe use one more cleaning with the soap, my hand got a little red applying the tung oil. All three are very well filled and smoother than many of my other handles that were well-scrubbed with the "multiuse" formula and now bear many coats of oil and have had several sandings back down to nearly bare wood. Only question seems to be whether the Murphy's in the filled cracks will cause some problems later, like suddenly gumming up, or losing the fill. I'll probably oil, then sand down to bare wood with fine grit again on the "experiment" a couple of times and let things dry out for one or two days before applying another coat of oil just to be safe. But things look pretty darn good so far.....And the red rouge/wax looks better in the grain than a sometimes cloudy oil fill I sometimes get. (maybe I should let dry longer than 1 day to avoid this cloudiness?)
 
NICE!!! The "King Chuck" crown rests not easily on mine head :D Wet sanding with the Murphy's concentrate never occurred to me, but the next one in will get it.
I don't think any fill left in the grain will loosen after drying and oiling. Only the caked-in rouge and wax was removed from the M43 scales I mentioned, as sanding would have ruined the texture the buffer had left on the hard grain. No sign so far of anything coming out. There is a a commercial walnut filler called "French Red" which is rubbed in wet, and intended to be oiled over when dry - same thing, for practical purposes, and it stays put.
The cloudy effect is probably early polymerization happening on the wood instead of in the container, set off by the combo of ingredients. I haven't had this with the newer Formby's or later Tru Oil. Both outfits appear to change their formulas (Formby's recent warning of "aliphatic hydrocarbons") which is why I like the "prepared" products over the ones closer to raw tung oil.
The handle that had been "hoofed" is finally taking a set, but it would have been faster and just as beneficial to have done it your way. 20/20 hindsight (rear-view mirror Deja Vu :)) can be a learning tool.
 
I showed this thread to the dust bunnies and they left in disgust before they finished reading it. I guess that's the difference between a dust bunny and a woodchuck.

Good stuff and good info.
 
Thanks for the comments Wal, it's good to hear that you don't think there will be any problems. After drying overnight, There are a few spots that seem to lack appreciable fill, but I suspect that they weren't buffed as hard when the original finish was applied. And/or they were mostly filled with soap that has now sunk in deeper. Anyway, it sure was a faster way to go, if it does work. Another plus that I forgot to mention, is that I was able to sand down the edge of the buttcap while working on the third sanding without getting any metal worked into the wood. I could see that things were not open adjacent to the buttcap. And I sanded out the grooves next to the rings first, as soon as I could, after applyling the soap since if much got in there, it could be a lot in a small area and might soak in a lot deeper. On a deeply checkered Chitlangi handle, it might be possible to leave a little rouge evenly distributed in the carving, which would be a nice effect.
 
Thanks, both of you, this is going to help a lot. Uncle Bill, is there a technical reason for the coat - does it help protect the handles during transit (and transition between different climates) better than linseed oil? I mean, people seem to be removing it, & I know I want to.
 
Irregular -
The rouge coat we commiserate over is a result of the final polishing of the knife. The rag wheels of the buffer are coated to polish the blade and brass, and it necessarily gets on/into the wood. Some of the handles are cleaned better than others, and some are waxed or oiled before the rouge is completely off. The rouge isn't protective - just incidental. Trying to add an extra step at BirGorkha isn't conducive to prices or earnings, and those of us who like to fancy-up the handles just consider it a nuisance, along with the other finishing steps. The Murphy treatment is great for removing most of it, and firkin's wet sanding with Murphy's should completely resolve rouge as a problem. Also, Murphy's on wood is like chicken soup (it shouldn't hoit:))
 
Wal, sometimes there's gobs of the rouge/wax, or such a heavy coat, that it's hard to believe that they aren't mixed intentionally. Unless they use the same wheel sequentially for both operations... Anyway, the mixture sets up pretty hard, as we all know. Makes for a not unatractive, fast and simple way to convert rasped wood into a smooth handle. Pretty efficient. I wonder if the wax alone would set up as hard. I'd rather pay less for the knife and put in the work myself so I can buy more knives.

BTW, after one fairly good sanding of a tacky tung oil coat, followed by a heavy coat of tung oil (That Murphy's does make the handles really soak up the first couple of coats of oil) and the AA, I think it's may be steel wool from now on:) :)

Just gotta keep my grubby hands off a couple of days so the initial heavy coat really sets up....
 
Good Stuff like this ought to go into the FAQ or something.

As far as the wet-sanding Murphy's concentrate goes, let's wait until it's not an experiment anymore and really works a couple of times to a final finish before something like that's considered. Still seems good and I'm hopeful.
 
I'm certain the same buffing wheel is used for both blade and handle. Remember, the kamis get paid for what they produce and this is an incentive to get the job done as quickly and easily as possible. The only thing that keeps the quality as high as we find it is a greater incentive to get the per piece pay PLUS a quality bonus or some other valued perk.

I'm still going to post that pix of Bura using the hand grinder. I've never seen a hand grinder in any arun in Nepal. They didn't even have one at BirGorkha when I was there. I've noticed that Bura's production has gone up rather dramatically and I know this is due to two reasons. One, Bura is getting higher tech all the time AND he has taken on an apprentice or two, something he had not done before. But with three wives to maintain what choice does he have?
 
Originally posted by Bill Martino
.......... But with three wives to maintain what choice does he have?

Suicide might be an option. One is more than plenty IMHO. :p
 
The only thing that keeps the quality as high as we find it is a greater incentive to get the per piece pay PLUS a quality bonus or some other valued perk.

And high quality it is. Sounds like both Pala and Bura are deptly managing a very tricky balancing act in this regard. That's gotta be really tough. I can't imagine going home to three wives after a day of that.
 
Bura is living with number three most of the time. Kesar has two or three wives living under the same roof. I don't know how they manage it. I sure as hell couldn't.

If HI standard quality is not met then the effort must be redone and this the kamis want to avoid like the plague. And, the kamis all understand what will constitute a reject and what won't and there is almost never any argument about what is a reject and what isn't -- they know as well as Pala, Gelbu or Pradeep -- but they will try to sneak a blem thru every now and then and sometimes they get away with it when things are rushed.
 
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