Lost Art Press

Category: Little Acorns: Profiles by Nancy Hiller

John Cox and the Lost Art of Traditional Coopering

Posted on by fitz
John with a pair of 800-gallon fermenting tanks called “washbacks” that he made in clear fir for Stoutridge Vineyard and Distillery

Question: What does that glass of Bulleit bourbon or Lagavulin Scotch have in common with a Chicago water tower and a wooden hot tub?

Answer: They all belong to the culture of tight cooperage, a subject on which John Cox is a fount of information.

I met John on a sweltering afternoon in 2018 while delivering a small piece of furniture to the Hudson Valley. Anissa Kapsales had invited me to meet her at John’s workplace, located in a large warehouse building on the outskirts of High Falls (population 627), about 90 minutes north of New York City. While I have long appreciated the fruits of the distiller’s art, I confess I hadn’t given much thought to the oak barrels that play such an important part in their production. John was the ideal person to enlighten me; a polymath with the personality of a showman and boundless enthusiasm for his work, he’s a natural teacher.

John was born in Philadelphia in 1969. His father was a tool and die maker who’d followed in his own father’s footsteps. They hoped John would become a doctor and not work with his hands. Oh well.

John (lower right) with his family: parents John, Joyce and brother Jay, Easter, 1983.

In high school John played music. He attended Muhlenberg College for a year of pre-med studies, then transferred to the Esther Boyer School of Music at Temple University. Many of his fellow students had been studying music seriously for years, and he soon realized that he was not in a position to compete – he’d never get a chair or play on Broadway. However, he knew some luthiers and thought “if I can’t play, I can build.”

He did a traditional apprenticeship with Richard Buccigrosse and John DelVecchio, who ran a millwork shop in his South Philadelphia neighborhood. Richard made flamenco guitars, in addition to fabricating millwork and repairing antiques. Richard was very strict – the shop culture was closer to that of a Philadelphia furniture shop in the 18th century than in the 20th. John worked full days in the shop, unpaid, then went to his job as a short order cook in a diner.

Affordable shop space was plentiful in Philadelphia in the 1980s; the recession had hit the area hard. John opened his own shop, and Richard sent turning and millwork jobs his way so he could spend more of his own time on flamenco guitars. On weekends, John took finishing classes with George Frank (author of “Adventures in Wood Finishing”) at the Olde Mill Cabinet Shoppe on the outskirts of Philadelphia.

Meanwhile – and this is where John’s story starts to sound like a Who’s Who of woodworking – the Snyderman Gallery, located a couple of blocks from John’s shop, was regularly exhibiting studio furniture. John developed a niche as a finisher, catering to local studio furniture makers and doing repairs and touch-up for the gallery. He specialized in ebonizing, French polishing and work with color, using a lot of aniline dye. At the age of 21 he found himself repairing a Gary Knox Bennett desk. Several graduates of Wendell Castle’s school had opened a group shop in Fishtown; John became the finisher for the group and worked with Michael Hurwitz and Peter Pierobon, among others.

In 1994 he took a job as foreman in a finishing shop, Finish Resources Studio, in New York City. They developed specialty finishes for designers, such as cerusing (decorative pore filling) for Tom O’Brien of Aero. “George [Frank] taught me the process,” John says. “It was us in the workroom that developed it.”

Four years later, he met Danish craftsman Jan Engberg and his son, Ian, who had a shop making high-end furniture; John ran their finishing shop from 1998 to 2001. “For the fourth or fifth time in my life, I find myself working with an old European master,” he says with appreciation for these opportunities. “I kept falling into these relationships with them, sort of avuncular. I’m very fortunate – to be working with these insanely talented older Europeans.” Working for the Engbergs, John did jobs for high-end interior designers such as Steven Harris (a protégé of Robert Stern) and Lucien Rees-Roberts. “Everything got published – Elle Décor, Architectural Digest. This was before Instagram,” he adds as a slightly wistful side note (that’s quite familiar to me). “We would never get pictures of anything unless it got published.”

Lucien designed some “wacky stuff,” says John, that was inspired by 20th-century designers Jean Michel Frank and Samuel Marx. They used a lot of goat skin, cow hide, leather, parchment and gilding, and produced pieces destined for swanky apartments in such upscale areas as Central Park West. Recalling the kinds of orders they got from the designers, John says “’Let’s do the rosewood tables we did for the last client…let’s do the leather closet doors we did for Cabo – let’s do that for this client, but bigger.’ They sent me to Cabo right during the mad cow disease outbreak … with 42 cow hides! I feel like we worked for everybody that ran Lehman Brothers,” as well as entertainers such as John Leguizamo. “They flew me all over the world. It was all custom work.”

Then came 9/11. “We stood on the roof of the shop and watched it go down,” John says. “It affected our business. I wanted to leave New York.”

At a finishing convention in St. Paul the following year, he met Greg Johnson, who worked for Wendell Castle. Wendell had opened up a 42-man furniture factory called Icon Design outside Rochester; they were so busy they’d reached a bottleneck in production. Greg asked John to join them, and he did. As you’d expect, the work was meticulous. Each piece involved about 21 quality control checks, right down to razor-fine specs for the sheen of the finish. While working for Wendell, he met the sculptor Albert Paley and took on jobs for him, too, flying to installations around the country where a piece of work needed repair due to damage suffered in a move.

The downside: all of this work involved a lot of chemicals. John was spraying urethane and lacquer – “doing great things that were not good for me. But I got really good at it and got a reputation…”

After a year in Rochester, he was ready for a change of scene. They moved to the Hudson Valley, where John opened a one-man shop combining restoration work with commissioned pieces like a goatskin side table. He found himself running all over the area for jobs that barely paid the bills. Even with freelance gigs for Albert Paley, it was tough to make a living.  

One day in 2015 John was talking with a friend who planned to open a mushroom-growing operation. “I said ‘I’d love a change. Why don’t you bring me in?’” His friend suggested something different. “Do you know there’s a barrel crisis right now? Why don’t you make barrels?” About a week later, Time ran an article about the barrel shortage, which has been exacerbated by a federal mandate that American distillers must use newly charred oak – in other words, a whisky barrel gets one-time use. Kentucky cooperages couldn’t keep up – they were working with lead times of 18 months. Craft distilling was a burgeoning business, but distilleries couldn’t find barrels.

John discovered that there was scarcely any information available on how to make barrels. Fine Woodworking had published an article about coopered joinery, and he found another on coopering by Tage Frid, but that was about it. It was truly, he says, a lost art. “So I bought three different barrels from three cooperages, took them apart and reverse-engineered them. It was a cipher. What’s the formula? It was like a cryptogram.” A cryptogram indeed – the research and development for Quercus Cooperage took more than two years. In the meantime, John was still running his furniture restoration business.

There are three types of coopers

1. Tight coopers make watertight containers.

2. Slack coopers make containers for dry goods. Everything shipped in the 19th century went in these containers, which were made by giant factories – nails, cotton, tobacco, salted meat and fish, gunpowder, oysters, fruit, cement.

3. White coopers have traditionally made household containers such as buckets, butter churns, bowls and pails. In Japan, white coopers made koji trays.

Cooper’s adze, used for pounding down the hoops. In the past, the blade end would have been sharpened and used to cut out a semi-circular groove at the top and bottom of the barrel.
The cooper’s adze was used to cut the chime and croze (top right).

When he heard about a large collection of 19th-centuring coopering tools for sale by a museum in Ottawa, he bought it. Then he set about learning what each one was, and how it should be used. “There was every tool you would need in a cooperage. Some looked familiar; some I had no idea what they were. Eric Sloane had some of them in his books; one of the first books Taunton did was a republication of a book of tools from England. I identified some from that.”

Next, he worked to figure out how to get his 20th-century machine tools to do what these hand tools did in the 1800s. “I held these 19th-century tools in my hand and said ‘How can I get my 3-horsepower shaper to do the same thing?’ How would I make this stave?’”

Here’s where his jazz background came in handy: there’s a lot of math in both fields. “Embracing the mathematics behind it really helped me figure it out,” he says, noting that Johannes Kepler had laid the groundwork for calculus by trying to figure the volume of a wine barrel. “It was becoming an obsession.”

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Using a winch to pull the barrel together after it has been steamed.

He broke the process of barrel-making down into five stages:

1. Acquire and air-dry the wood. It has to be air-dried, not kilned. He bought locally grown oak logs and had them quartersawn, then stickered.

2. Mill the staves. He had shaper knives custom-ground.

3. Find the steel for the rings, then make the rings and hoops.

4. Toast and char the oak to the client’s specifications. Toasting the sugars in the wood is an art that can make or break a whiskey.

5. Assembly. The point is to make a watertight cask. “It can’t even have a pin hole.”

On Dec. 22, 2017, the Winter Solstice, John succeeded in getting a barrel to hold water for the first time.

He’s now one of 33 cooperages in North America, and he makes his barrels largely by hand. A cadre of “meddling woodworking friends, machining savants and a welder” have helped along the way. As with most highly skilled custom work that uses top-quality materials, the economic side of the business remains a challenge. The wood for a barrel comes in at around $150. You can buy a barrel for less than half that from a major manufacturer.

John recently expanded into another of the traditional cooper’s arts: tanks for fermentation. Stoutridge Vineyard and Distillery, his regular client in Upstate New York, asked for an 800-gallon tank, the kind used for Scottish whisky. Adds John: “That’s also what the soy sauce guys ferment in. Before Covid hit, everyone was starting to make shoyu. But no one’s making barrels for shoyu; they were using stainless steel. You’re not going to get the flavor profiles you want from fermenting in steel. In Japan they use open-tank traditional wooden fermentation. No one makes them here.” He made a 2-gallon prototype, and things took off.

Two-gallon kioke made in fir, used for shoyu production. The contents are soybeans and fermented rice. John points out that the barrel is just the same form as the two 800-gallon tanks at the top of this post.

“I pivoted into this culinary world. This koji thing that’s happening – they’ve been fermenting rice for 7,000 years. No one in America was making koji trays. If I hadn’t pivoted into the culinary stuff last fall I don’t know where I would be now.”

Brad Leone of Bon Appetit discovered John through Instagram; a chef John knows had asked him to make koji trays, and his name and pictures quickly made their way around that community. “They came to the shop and posted some stuff and it really blew up. [People] want to do this traditional Japanese work” – think sauerkraut, or kimchi – “but they don’t have the traditional objects to make it.”

Still, he says, it remains challenging economically. Margins are slim. “I’m a struggling one-man shop no different from any other.” Every barrel is custom made and takes time. Even with the technical challenges involved in figuring out his methods, John says the biggest learning curve has related to shipping and logistics. Instagram has helped him market the work; it’s one thing to get press in a print magazine, but there’s a two (or more)-month lag between the writing and publication. There’s no lag-time in Internet publishing, which makes it easier to change course swiftly.

Because of Covid, John’s craft distillery and brewer clients are closed, so the culinary stuff is filling his time. There’s a market, for now; it’s also more affordable. He says he’s the only person making the small tanks in America right now and adds, “I’m 5’6” so they actually call me a mini cooper.”

—Nancy Hiller, author of Kitchen Think and Making Things Work

Pine Croft: the Little Woodworking School with a Giant History

Posted on by fitz
Image: Berea College Archives

In the fall of 2005 I found a message on my shop’s answering machine from Kelly Mehler, who had seen my Fine Woodworking article on designing built-ins and wondered whether I’d like to teach a cabinetmaking class the following summer at his school on the outskirts of Berea, Ky. I was single at the time, running my business with one employee and dividing my evenings and weekends between finishing my house (installing wooden floors and trim, framing and drywalling stud walls to subdivide the attic, painting) and establishing a garden. I’d recently turned 46 and had no grand vision for how I wanted the rest of my life to look; it was all I could do to keep things together emotionally and financially day by day. So Kelly’s invitation was like a ray of sunshine. I leapt at the chance to teach and chose the week of my 47th birthday for the class to ensure I’d have something cheerful going on.

Kelly Mehler’s shop and school. Image by Mary May from her blog post Back from Berea, KY

I was thrilled to find the school located in an idyllic setting at the end of a long gravel drive. Surrounded by rolling hills and forest, it was a two-story building with tall windows and plenty of natural light. There was an enviably equipped machine shop on the ground floor, a bench room above and air conditioning — a serious boon in the Midwestern summer. As an instructor, I stayed in the delightful cabin next to the shop, while Kelly and his wife, Teri, lived just up the hill in an old log house built for Swedish weaver Anna Ernberg, who had been hired decades earlier to lead the weaving program at Berea College. The class was small, the people friendly, the food great. I could not have imagined a happier introduction to teaching.

Kelly helping student Jim Ferrell during one of my classes, 2011.

Over the next several years I taught a few more times at Kelly’s school. One year, he and Teri invited me to join them for a Fourth of July party at the home of some friends whose house was high up on a hill with a great view of the fireworks display. A bunch of people at the party worked for Berea College, and I was fascinated to learn a bit about the institution, which is committed to educating the young people of Appalachia and — astonishingly — tuition-free. What a concept, especially at a time when so many students go tens (or even hundreds) of thousands of dollars into debt for a college degree!

Fast forward a few years. Kelly and Teri had retired and sold their property to Berea College, which re-opened the shop as the Woodworking School at Pine Croft, with North Bennet Street School alum Andy Glenn at its head. Andy contacted me to ask whether I’d like to teach in the summer of 2020, and we settled on a week-long class on my version of Voysey’s 1898 design for a two-heart chair. We also agreed that I would give a presentation one evening about English Arts & Crafts furniture for students and members of the local community who might be interested. The topic seemed ideal because I could see all kinds of parallels between the values upheld by Berea College and the philosophy of John Ruskin that had given the Arts & Crafts movement its spark. For example, Ruskin held that traditional craft work, pursued in circumstances that allow the individual craftsperson some freedom of expression, poses challenges, requires endless learning and allows for wholesome satisfactions, all of which Ruskin thought essential to a fully human life. Nor did Ruskin wish a fully human life only for those of his socio-economic level, but for all.

That class would have taken place a few weeks ago. But as with so many other events this year, it was cancelled, along with the other classes at Pine Croft scheduled for 2020. Berea College was among the first to send students home and end on-campus activities in March, the decision based on the institution’s avowed commitment to the kinship of all people and the dignity of all labor. Such respect implies “an obligation for each other’s safety and wellbeing.” said Aaron Beale, Director of Student Craft, when I spoke with him recently. He added: “We are lucky we’re in a situation where we can make those decisions. It seemed clear that we couldn’t start the summer with those early classes in May and June, and it seemed unlikely that there would be a miraculous change” going into the later months. It was a hard decision to make; Andy had worked hard to pull together a group of instructors for the inaugural season, but Aaron said “it didn’t seem right to string people along for something that wasn’t likely to happen at all,” considering that classes would have involved people traveling, then being taught in confined spaces.

Despite the cancellation, I wanted to learn more about how Berea College’s commitments expressed so many of Ruskin’s convictions regarding education and work. So I arranged a conference call with Aaron, Andy and Chris Miller, associate director and curator of the Appalachian Center.

Savannah Smith, Jamie Schlabach and Sophia Gueye (Photo: Justin Skeens, courtesy of Berea College).

History

Founded in 1855 by John Fee, a Presbyterian minister who was an abolitionist, Berea College originally focused on providing an education to freed people of color. That mission changed in 1904, when the college was forced to segregate by the Day Law. The college, Aaron told me, “elected to focus on the education of white students from Appalachia here in Berea, and split its endowment to also form The Lincoln Institute in Shelby County, Ky.” This school operated as an all-black boarding high school from 1912 to 1966.

“At that time, a college education was far rarer than today,” Chris elaborated. “It was considered elite. Berea was a pioneer in educating common people, whether freed slaves, children of farmers, whatever. One of the ways we differed from other colleges providing a liberal arts education: we had a more progressive idea of what education means.” Leaders of the college’s policies integrated the ideals of the Sloyd and YMCA movements, which focused on educating the whole person. Early in the 20th century they ran an outreach program — a preacher would preach a sermon, then someone might provide the latest instruction on planting beans, followed by someone else discussing Shakespeare. (Returning to echoes of Arts & Crafts values, this was not unlike the broad range of character-enriching programs offered to members of the local community by Englishman C.R. Ashbee’s Guild of Handicrafts when it moved to the Cotswolds, west of London: the idea was to provide education for everybody and for the whole person.)

Since then, the leaders of Berea College have continually experimented with how to put those same ideals into practice. Today, for example, in addition to programs in agriculture they have emphasized organic and sustainable local agriculture. Another example: the college has a four-year liberal arts nursing degree — nursing is not typically taught in the context of the liberal arts. There’s a program in technology and applied design, and all students in the business school have to take the liberal arts core. A program called “Entrepreneurship for the Public Good” responds to the urgent need to create sustainable businesses in Appalachia, ideally to encourage students to stay in the region instead of leaving. “We expose them to an ethic of service,” Chris said, “because it infuses the institution.”

Since 1892 the college has been tuition-free. How do you manage that? I asked. The greatest factor in making it possible is a $1.2 billion endowment. Unlike most colleges with substantial endowments, which re-invest interest income back into the endowment, Aaron pointed out that Berea College “puts 100 percent of the return…to work for students, paying their tuition and offering the other programs that make Berea so special.” Another significant factor is that most students qualify for federal, state and other financial aid. One of the most unusual features of Berea College is its student-run income-producing enterprises, such as the college farm store and the Boone Tavern, which the college built in 1909 to house visitors and still operates today. From its inception, the tuition-free education has also depended on income from the sale of student-made products in the crafts of wood, weaving, ceramics and broom making. Beyond attempting to generate income for tuition, these enterprises broaden the range of educational offerings to encompass hands-on skills that are rarely taught at academic institutions of higher education.

Despite all these sources of tuition-supporting revenue, the college must still raise $4 to $5 million annually through an appeal to donors known as “The Berea Fund.”

Horse logging at the college forest (Photo: Berea College).

The college also has a Forestry Department — appropriate, considering that the institution owns nearly 10,000 forested acres held in a carbon sequester program. It’s the oldest privately managed forest in Kentucky and one of the oldest in the entire United States. Berea College has been a pioneer in managing forest sustainably. They log in the least-damaging way — with horses — and just hired a second team of horse loggers. Although the college does not offer a degree in forestry as such, its forestry studies are run through the agriculture department. Wendy Warren runs the forestry outreach center and lives in the cabin where instructors at Kelly’s woodworking school used to stay.

“It really is all about the forest,” added Aaron, returning to the reasoning behind the college’s purchase of the Mehlers’ home. “The [Pine Croft] property is about 15 acres and borders the college forest on two sides. We didn’t want to see that property subdivided into 15 properties.” The Mehlers’ former home also included two structures that tie in with the college’s mission: the main house (now a bed and breakfast, which fits the mission of bringing people into the forest) and the woodworking school, which furthers opportunities to live up to one of the college’s principle missions, a commitment to the dignity of all labor, not just white-collar professions.

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Pine Croft Cottage, the Mehlers’ former home (Photo: Berea College website).

Berea and Craft

The town of Berea, which grew up around the original college, has long been recognized as a center of craft and cultivated a market for tourists interested in buying work that’s locally made. In recent years, Berea’s approach has shifted from simply promoting the sale of completed objects to exhibitions of craft in process, as well as encouraging visitors to participate in the making. This, too, factored into the opening of the Woodworking School at Pine Croft. Although Berea College has long had a woodworking department with staff instructors, Pine Croft would allow the college to bring other craftspeople who teach into the area. “The college has been limited vis-a-vis student craft,” Andy explained. “There are typically 20 to 25 students; most have never held a woodworking tool before their first day. Pine Croft allows us to expose our student population to master craftspeople and brings master craftspeople into the region, which is important to the mission of college. Again, it’s about the dignity of labor. Woodworking is a trade that deserves respect. Bringing high-quality work to the area is another way the college sees itself partnering with the region” — to which Chris added: “It helps people see that Appalachia is not just a ‘deficit situation,’ but has a lot to offer the world.”

Andy’s job goes well beyond teaching; he’s also responsible for making products for sale — rolling pins, cutting boards and a wooden stool with a hickory bark seat, the last of these made with wood and bark from the college forest. The proceeds from sales help support the costs associated with tuition.

The Forest Stool (See Berea College Shoppe).

“My job is to train the students so that we can make the crafts,” Andy explained. This is not as simple as it sounds. The most profitable way to make these items would be by adopting some modified form of assembly-line production, in which each student would master just one part of the process instead of learning the whole. But that would be inconsistent with the college’s commitment to training students for their own benefit in addition to giving them a way to help support their own tuition. It’s a challenge to convey the richness of handcraft while being as productive as possible.

“It’s a real tension,” Aaron acknowledged. “Andy has two jobs that are compatible, but both extremely demanding — running wood craft, the woodworking component of the student craft program, but in addition, Andy also is the head of the Woodworking School at Pine Croft. Andy really does do two separate full-time jobs.” As with the other student craft programs, the goal since the 1890s has been to run an enterprise to support the running of the college. Aaron conceded that for the past century, these programs haven’t made a profit; in fact, they regularly run a deficit. But instructors and students do still approach the work as a business; they face real production demands, as opposed to the ethos in most craft schools, which allow students a temporary respite from the financial and time constraints of regular jobs so that they can really focus on mastering skills. Andy has to teach and provide an environment that links up with the college’s mission, all while turning out saleable goods.

Set of 18 chairs for the college president’s home, awaiting oil and finish, then upholstery. Cherry and maple, 2020. This was originally a student crew project before concern about Covid-19 shut down classes on campus. Andy completed the chairs after the students left for the semester. The chairs are based on Federal-style chairs made in the Portsmouth, NH, shop of Langley Boardman circa 1800-1815. Andy designed the project to fit the style of the president’s home and utilize, as well as stretch, his student crew’s skills.

The wood craft program also takes special orders, which make up between 30-40 percent of their work. These jobs have run the gamut from simple recycling bins with solid wood doors to pieces of fine craft, such as a recent run of 18 chairs in the Federal style for the president’s home on campus. Andy and the students will also build a 17’-long table. In addition, Andy has increased the use of hand tools. The same elevation of appreciation for material culture applies to the other craft departments. As Andy put it, “We’re making items that have a story to tell, that we can be proud of and that link to the college values.”

Azariah and Andy.

With students off campus (there would ordinarily be about 20 of them helping), Andy is running the shop’s production with his shop assistant, Natalie Brown, who gained her woodworking skills during a residency in art at the University of Iowa. 

Andy Glenn

Andy and Sarah with Ruby, Francis and Oreo (not pictured: the family’s Maine Coon cat, Elsie).

Andy joined the staff in 2017, when he was hired as head of wood craft. He and his family had been living in Rockport, Maine, where he worked as a woodworker after teaching and working in other capacities at North Bennet Street School.

Woodworking has always been an integral part of his life. Both of his grandfathers had wood shops; one worked on a 150-acre farm outside Ashland, Ohio, while the other, who lived in Ashland and worked as the town milkman, had a small basement shop where Andy spent a lot of time making things.

Andy graduated with a degree in business economics from the College of Wooster, Ohio. In 2004, straight after college, he and his wife, Sarah, got married. They moved to Cambridge, Mass., so Sarah could pursue a master’s degree at the Longy School of Music. Andy found work as business director for a school but realized the job involved too much administration for his liking. “I was chasing numbers all day,” he laughs, recalling himself thinking “’Look at my hands. There are no callouses anymore!’ In a weird way I recognized I just wanted to work with my hands.”

North Bennet Street School was two miles from where they lived; he took some classes, then went through the cabinetmaking and furniture program from 2006 to 2008. While he was a student, he also did a significant amount of teaching, worked as caretaker for the building and helped create the curriculum for (in addition to teaching in) a middle school program that was a partnership between NBSS and local public schools.

Despite all of this extracurricular work, he had to take on some debt. He found himself graduating into the Great Recession, which was daunting, but says “I was still excited. Still am. Which has served me well as a woodworker.”

Armoire. Curly and birdseye maple, student project at NBSS, 2007.
Chest of drawers, cherry and pine, 2009.
Spider leg table, cherry. 2012, based on an 18th-century English table.

Sarah graduated with a degree in violin performance, then went on to work for the Boston Symphony Orchestra as assistant manager of Education and Community Engagement.

Meanwhile, Andy had become friends with Freddy Roman as a student at NBSS. When Freddy left his part-time employment with Phil Lowe at the Furniture Institute of Massachusetts, Andy took over his role.

His next job was back at NBSS. At that time, he says, the school “was in an old structure, three buildings cobbled together to make one. I was on site for troubleshooting and routine (and after-hours) care. There were annual issues with fires in the sewer.” Having someone on site was critical. He also did such mundane jobs as taking out the trash and says “I loved every moment of it…. The school moved around the time I left, though it only moved a few blocks within the North End neighborhood of Boston. The new school building was renovated and outfitted to house the growing school.”

Andy and Sarah had a daughter, then a son. As the school was getting ready to move to a new location, Andy moved on to a position with a shipyard in Belfast, ME. “The dream was making wispy shavings on wooden boats. The reality was, I was a wearing a Tyvek suit grinding fiberglass. It was the job. In a weird way, I enjoyed it, but I only enjoyed it because I left it. Those people put in hard days and they love boats. Boats are something in your blood. They would come to work on these boats and ships, talk boats at lunch, and go home to work on their own boats.”

Next he got a job at a cabinet and furniture shop, Phi Home Designs in Rockport, ME, which made high-end residential cabinetry and furniture commissions. Andy did both. “That was a great position and a great education.” After leaving that job, he started doing his own work, piecing his income together from multiple sources, including commissions outsourced by other shops. He also taught at NBSS one week a month. “That was going well. I was working hard. But it wasn’t working for our family for me to be gone a week per month. Sarah was at home with the kids in midwinter. My travel and unpredictable schedule put too much stress on our young family.” They were open to something different.

Had they stayed in Maine, Andy would have had to get some kind of more stable employment with benefits, almost certainly not in woodworking. “I love woodworking,” he explains. “But it’s definitely secondary to family. I was really excited and grateful when the job opening came up in Berea.” He started the job in the summer of 2017.

“The students here are wonderful,” he says. “There’s very little entitlement. The students are grateful for the opportunity. They’re thankful to be at the college. Most of the students who work in the shop — you never know how they’ll use these skills going forward.”

Custom table with building crew Marrone, ‘Minta and Tim.
Chase Slone, after making six shave horses.

Andy wrote to me separately that when it’s safe to resume classes at Pine Croft, Kelly Mehler will return to teach (and just generally be around the place) as often as he likes. Andy, too, will be teaching a number of courses. He asked me to point out that in choosing visiting instructors who are deep in knowledge, skills and expertise within the field of craft woodworking, he and his colleagues bore in mind the interracial and coeducational ideals and commitments of Berea College. “Our goal is to put together a roster that is representative of the woodworking community,” he wrote. “Much like Kelly created, my hope is that the school is a welcoming and special place for people to gather to learn woodworking.”

“I’m proud of the schedule and of our visiting instructors for the first season,” he added. “I’m certain the strength of the visiting staff came together because of the school environment and community that Kelly and Teri created. Peter Galbert and you [i.e., the author of this post] had taught at the school before. Megan Fitzpatrick cut her first dovetails with Kelly at the school. [Megan clarified that they were her first dovetails cut entirely by hand and noted that she has visited the school on multiple locations and loves the place.] I am grateful that Michael Puryear, Cathryn Peters and Brendan Gaffney were open to joining us for our first year.”

— Nancy Hiller, author of Kitchen Think, English Arts & Crafts Furniture and Making Things Work

Joseph and Corey checking a case for square.
Wood craft crew, 2018.

Laura Mays: Making the Connections Between Building and Design

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Teaching at The Krenov School, with second year student Scott Nelson. (Photo: Michelle Frederick)

While on a bicycling vacation in 1994, Laura Mays found herself at a village crossroads in remote County Galway, on Ireland’s western coast. Each of the first three corners housed a pub; the fourth, a large Victorian building. Intrigued by the architecture as well as the structure’s status as the odd one out, she stopped to look around.

She learned that the building had been a boys’ reform school – one of those infamous institutions where abuses of children, sequestered from public view and in the charge of authorities subject to scant oversight, were routine. After the place was decommissioned in the ‘70s, it became home to a woodworking school, Letterfrack, part of the Galway-Mayo Institute of Technology. The school employed instructors from England, most of them graduates of Parnham College, the renowned institution started by John Makepeace.

For Laura it was a moment of serendipity, a crossroads as figurative as it was literal.

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Laura with her brothers, Sam and Tig (short for Tycho)
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Laura (right, center) with Sam (front), Tig (the little blond) and her mother, Marianne, a professor of English who taught for Britain’s Open University, a pre-internet correspondence course-type means to study toward and earn a college degree.

Laura is the second of three children born to parents who were both professors of English; they met as students at Oxford in the 1960s. (They are now retired.) Shortly after her father earned his doctorate they moved to Ireland, where he taught at University College, Dublin. Laura arrived in 1967 and grew up in the suburbs with her two brothers. She remembers it as “very homogenous, white, Catholic,” though she’s quick to note “we were classed with the Anglo-Irish, who had been in Ireland for the previous few hundred years, ‘planted’ there by various English monarchs, and basically the oppressors, [e]ven though we had arrived very recently. I think also being gay made for a marked feeling of separation and difference.”

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Laura (in brown) with her brothers and father, Jim, a professor of English who, among other feats of scholarship, has edited the collected poems of Coleridge for Princeton University Press.

A quiet child, she spent her time reading, drawing and in art classes and has happy memories of swimming in the ocean every summer. When the time came to think about university, she settled on architecture. “I was one of those kids who was good at everything,” she explains. “Architecture school seemed like an all-around education.” (She suspects her father’s longstanding interest in the field and her older brother’s prior decision to pursue an architectural degree may have influenced her thinking.) It was five years of instruction, with heavy emphasis on historical perspective – “a fantastic basic design training,” she says. “But when it came to working as an architect, I disliked it intensely, [down to] the smell of the carpets in architects’ offices. I hated going out on site where all the guys were; they already hated architects, and here comes a young woman telling them to do stuff that is not as convenient for them. I found the disconnect between building and designing very off-putting – telling people to do stuff that I didn’t know how to do.”

After working in that field for a couple of years she decided it was time for a break. She spent a year in New York and six months in Japan, taking any job she could get to scrape by. On her return to Ireland she worked as assistant to a graphic designer – the job that allowed her to take the bicycling vacation at the start of this story.

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A dry stone wall undulates with the land at Salruck, near Little Killary, County Galway, near where Laura and Rebecca lived and had their workshop. Laura says “the valley had been home to almost 1,000 people before the Famine in the 1840s. When we were there there were about 15 of us.”

Having found a woodworking school right in her path, she decided to apply. “I had an inkling that making things with my hands would be holistic and engaging,” she explains. “As an architecture student I had enjoyed the making of drawings, and thought about them more as finished products than as a means to an end (to a building).”  She was accepted in 1996 and began her training that fall.

On the first morning of class students had to flatten the soles of their planes with glass and carborundum powder. “This is really serious,” Laura remembers thinking. “They were teaching us something that was going to be high quality. It was everything I had missed in architecture about making stuff – [here] the implications would be on you. You would see the continuum all the way through.” She completed a two-year program in design and manufacturing. “They were training us to work either for industry or for small-business owners making one-off furniture on spec.” The student culture was intense – “we were really, really keen, all of us,” she says – so much that they would secretly prop the workshop door ajar when they went home on Saturday night, so they could sneak in Sunday morning.

After graduating in 1997 she moved back in with her parents, who had relocated to a farm in County Wicklow, near Ireland’s central-eastern coast. She took over a couple of outbuildings to use as a furniture workshop but notes that despite her training, “quickly I realized how little I knew!” She subscribed to Fine Woodworking and gleaned all she could from the pages.

Meanwhile, her friends were settling down and having children. They’d approach her about furniture for their houses. After making several large tables where families would gather happily for meals, she couldn’t help reflecting on her own situation as someone nearing 30 and living with her parents. As she puts it, “There was definitely something missing.”

It was during this period that she came across the books of James Krenov. “Something about the way he wrote I found very engaging,” she remembers. “He talked about failure.” Before that, everything she’d read seemed to be about the shiny, the perfect, the most efficient. He proposed a different approach. She looked at the back cover and saw the bio. “Teaches and lives in Fort Bragg, California.” She looked the place up on Google, a relatively new phenomenon at the time. Up came a website: College of the Redwoods. She sent a note by email. “Before I knew where I was,” she says, “I was on my way to Northern California to study at the school.” Would she hate it? She figured she could always go home.

As things turned out, she loved it. Following her graduation in 2003 she returned to Ireland, where she taught at Letterfrack for eight years. In her spare time she pursued a master’s in design through an online program of the National College of Art and Design in Dublin, adding another credential to her résumé.

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Teaching at The Krenov School, with student Carlos Cux. (Photo: Libby Lewis)

Laura may well have continued to teach at Letterfrack, had she not received a note from the College of the Redwoods in 2011 asking whether she’d be interested in applying for the position of director. Krenov had retired in 2002. Michael Burns, who’d held the position of director since the school’s founding in 1981, was about to do the same. She applied and got the job.

“When there isn’t a pandemic,” she observes wryly, she teaches 22 hours a week. An important part of her work is getting to know the students well enough to be able to help out when emotional, financial and other challenges arise. She also liaises with the part-time faculty (Jim Budlong, Greg Smith and Ejler Hjorth-Westh) and with shop manager Todd Sorenson; oversees the budget and admissions; and handles the school’s publicity and social media.

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“I think it’s a really, really good program,” she comments, immediately deflecting the praise away from herself: “They set up a really good program in 1981 – deeply immersive, a 48-hour minimum week, six days a week, very intensive. Students learn a lot from each other…. We’re fully committed to passing on the craft as well as we can, really trying to help people understand the material. To see. To use all their senses to gather information and be responsive to what’s going on. I see it as a gift I am passing on. I was given that gift and I like to give it to others.”

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“Fool’s Gold.” A small box made in old-growth redwood (reclaimed) with gold leaf on interior.
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“On In” cabinet. Madrone carcase, yew and walnut drawers and doors, red oak drawer sides.

Instead of finishing up the 2019-2020 academic year with 23 students in the shop, Laura had to shut down classes on March 20. The plan: switch to teaching online. “But it’s so antithetical to everything about the program that it really didn’t work very well,” she concedes – not that this will come as a surprise to anyone who has been attempting to teach or study woodworking this spring. While it’s true that students would ordinarily have been working on projects more independently by that point in their training, she and her students have missed the camaraderie and celebrations that customarily mark the end of the school year. Some students found garages or other spaces to work in; another finished up her coursework with a paper outlining how she would start a furniture business in South Africa, her homeland. Things will be different in the fall, with changes designed to enable social distancing. Instead of a 17-week class for 23 students, there will be a six-week class for ten students, with a plan to hold more frequent classes of smaller size and shorter duration.

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Skew box in Irish oak.
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Bowen Chair in ash. The table was designed to accompany it by Krenov School student Timber Dubin.

Still, Laura has her work cut out for her. Not only does she have the usual complement of administrative work she faces every summer (the Krenov School is a program of Mendocino College); she’s also collaborating with Deirdre Visser on a book about women in woodworking. (They started the project with a third collaborator, Phoebe Kuo, who understandably found the pressure of juggling the book with her workload as a second-year MFA student in Design at Cranbrook Academy of Art overwhelming.) Making a Seat at the Table: Women Transform Woodworking grew out of a discussion with Deirdre, curator of the arts at the California Institute of Integral Studies, when she was a student at the College of the Redwoods in 2015-2016. The basic premise is to show that despite the relative invisibility of women in the field – at least, until the past few years – women have been building with wood for as long as woodworking has existed; examples in the theoretical section of the book go back as far as 4,000 BCE but become more widespread in the Middle Ages. The book also includes profiles of contemporary women in woodworking and illustrates the diverse ways in which women are making their impression on the field. The book is under contract with Routledge; although it’s not yet scheduled for publication, it may appear as soon as summer 2022.

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Laura and Deirdre at the opening reception for Making a Seat at the Table exhibition, 2019

Related to the book, they organized a show of work by 43 makers that ran from October 2019 through January 2020 at Philadelphia’s Center for Art in Wood.

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With Rebecca Yaffe, Laura is also mother to a daughter, Thea, who was born in 2012. “She’s amazing,” Laura says. “Very strong-headed. Smart. She’s emotionally more intelligent than I am, for sure!” Laura and Rebecca met when both were students at the College of the Redwoods and moved to Ireland together. They shared a workshop there when Laura was teaching at Letterfrack and returned to Fort Bragg together, but have since split up. It’s an amicable split; they co-parent, each taking Thea half-time. “Being a parent is like ‘all the things,’ says Laura. “Too hard to explain! It’s great and it’s boring and it’s tedious and it’s wonderful. It’s planning all the time. It helps me; it’s made me more organized.”

You can see more of Laura’s work at her Instagram account.

–Nancy Hiller, author of Making Things Work

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Thea at Glendalough, County Wicklow, Ireland
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Thea at the beach in Northern California
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“I made the chair at half-scale,” writes Laura, “as a model for an adult chair, then realized it was perfectly scaled for Thea, then aged two. I’ve discovered that children hardly ever use furniture in the intended way.”

And now, enjoy some gorgeous Irish scenery provided by Laura.

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Across the Board: Yoav Liberman – Furniture Maker, Teacher & Finder of the Good

Posted on by fitz
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Yoav’s drawing for his knockdown table “Merritt,” made with reclaimed materials, inspired by the Merritt Parkway

Imagine this: You’re a teacher of woodworking. Your students are kids. The school where you teach is in a big city, and most of your students live nearby. It’s March 2020: Your school, along with much of the rest of the world, shuts down in response to the pandemic. But your job is to go on teaching. What do you do?

This is the reality that hit Yoav Liberman three months ago. His students and their families were in lockdown, confined to their homes in New York City, which has suffered some of the world’s highest numbers of infection and death from Covid-19. Instead of teaching face-to-face in a workshop at Manhattan’s Rudolf Steiner school, as he has for the past eight years, he was expected to teach remotely, via computer screen. “How do I participate in this in a meaningful way?” he wondered, aware that his students lacked access not just to workbenches and woodworking tools, but also to lumber. With parks closed, and few trees on the streets, “even getting them a branch would be almost impossible.”

Fortunately for Yoav’s students, their teacher has a lifetime’s experience of turning challenges into opportunities.

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Yoav with his father, Eliezer, and brother, Dan

Yoav was born on the outskirts of Tel Aviv, Israel, and has one younger brother, Dan. His dad, Eliezer, was a machinist, handyman and maritime officer who worked as chief engineer on a merchant ship. Thanks to his position, Eliezer could bring his family along in the summers; Yoav recalls two-month voyages from Haifa to the Mediterranean, then on to America and Canada. It was the late 1960s. Ships were small. The world was not connected as it is today. “Those voyages are a very important part of my childhood memories,” he says. They might stop in Athens, where they’d pay a quick visit to the Acropolis, then in a day they’d be in Florence. Another day would pass and they were in Marseilles; then they’d cross the Atlantic. In addition to providing a dazzling introduction to different landscapes and architectural styles, those vacations opened Yoav’s eyes to the world of engineering and mechanics. “I was seeing the world not from a luxurious point, but from a merchant ship perspective,” he explains – and as often as not, he was immersed in the guts of the ship, because it was his father’s job to keep things running, through storms as well as calm seas.

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Liberman ancestors in Czechoslovakia, 1930s. Yoav’s father is at far right.

 

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Yoav’s maternal grandparents

When Yoav was 6, his father died, an experience that had a powerful effect on the course of his life. Aside from the emotional wounds caused by such a loss, especially at a young age, he and his family were forced to learn a multitude of new skills. His mother (today, a retired school teacher) and grandfather were now responsible for fixing things around the house. Yoav has a vivid recollection of watching his mom mix epoxy. “In other homes the only glue that people used to use was silly contact cement, [but] my mom kept two epoxy tubes that my dad got from one of his trips to the USA and taught her how to use.”

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Yoav with his maternal grandfather

“I was not such a good student in elementary school,” he says. “My mom said that I ‘withered inward’ after my dad died. Without any academic achievements to be proud of, I was destined to attend a vocational high school, which actually ended up as a godsend. With a curriculum that included machining, plastic and polymer studies, robotics and electronics, and most importantly, technical drawing, I was in heaven. At home I [built] scale models of ships and planes, and in school I leaned over a metal lathe to turn a hammer head or held an acetylene torch to build a small garden stool.”

Like all able-bodied Israeli citizens, Yoav did a compulsory stint in the armed forces – in his case, the navy – then considered going on to higher education. He didn’t want to study pure engineering, but he wanted to do something involving art that would also be functional. There were no furniture making programs in Israel at the time, so he thought “I’ll just try architecture. You design buildings and furniture, get training that’s lofty in terms of art and principles of design but also down-to-earth training in materials and construction.”

The summer before he started his studies at the Israel Institute of Technology (Technion), he worked for a family friend who had a woodshop. The work was low-level and mundane, but that shop launched him on his lifelong project of collecting wood scraps and other materials that most people throw away.

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With his mother, Ruth (lower right), aunt, uncle and cousins, mid-1990s

Yoav completed a five-year program in architecture at Technion. It was the early 1990s, before widespread publishing on the internet. His teachers were architects, not woodworkers. To get his woodshop fix he subscribed to Fine Woodworking and devoured the content. As his interest in woodworking grew, so did his collection of tools.

After graduation he “gave architecture a chance,” as he puts it, by working at a couple of small firms. But he spent his spare time building and restoring furniture. While he enjoyed some of the sketching and 3-D work in his architectural apprenticeship, he was put off by the layers of mediation between the clients, the work and himself. “You’re so remote,” he explains. “There are so many hurdles to jump over. So much red tape. Some are completely justified, [though] as a junior architect you’re even more remote. But working on furniture is so in tune. [You’re] so in touch with the material and the processes. It’s fulfilling.” An invitation to teach a class in furniture refurbishing and design at a small DIY center in Tel Aviv proved pivotal. “I was much more interested in that than in working in front of the computer to compile square footages for a building my boss designed.”

During his apprenticeship Yoav had also taught architecture, drawing and design as an adjunct professor at a community college. He kept that work going and began writing about furniture for a DIY magazine in Israel, as well as teaching classes in furniture refurbishing.

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Yoav

In the late ’90s Yoav’s (now-former) partner moved to Cambridge, Mass., to begin work toward a doctorate at Harvard. While visiting his partner, Yoav discovered the Worcester Center for Crafts; he made some inquiries and showed them his portfolio. Impressed, they accepted him as an artist in residence and sponsored his student visa. “It was a dream,” says Yoav. “The magazines were from New England, and many of the people [whose articles] I read were working in the Boston area.” It felt like destiny.

Yoav moved to Massachusetts in 2000. He lived in Cambridge and commuted to Worcester. His job: to build a meaningful body of work. He worked long days, grateful for access to the school’s resources and the opportunity to think about things he wanted to build. He also took classes in turning, jewelry making and glass. Looking back, he says, “I was in Candy Land.”

His collection of salvaged materials grew; he was constantly thinking about how to save stuff from being destroyed or thrown away. Reclaimed materials became the hallmark of his work. The city of Worcester contributed to his stash: He scored a bunch of heart pine beams from a mill that had been demolished for a highway. The firewood bin at the craft school provided riches, too. As Yoav saw it, “I was happy not to allow this material to be lost to the landfill but regain respect from its users or viewers for as long as the furniture I built would last.”

He sought out other teachers and found his way to the Powderhouse Woodworkers – Mitch Ryerson, John Everdell, Judy Kensley McKie and Nathan Rome, who had set up a co-op in an old millwork building rented from Tufts University; there was a communal machine space and kitchen, with open studios. Each member of the co-op had his or her own style. Yoav worked with John and Mitch; he particularly admired John for the complexity and variety of materials with which he worked and calls him “a virtuoso in using bronze and copper and stone and ebony.” Yoav wrote an article about John for Woodwork magazine.

Yoav apprenticed with the group on and off for about six years. Asked how he made a living, he replies: “My partner got a stipend from Harvard. We lived in a grad dorm. I was riding my bike to my mentors’ studio. We survived on his stipend plus my savings and some family support. We were very frugal. Officially I was a student, so I was not supposed to work.” (He has since been granted a green card.)

Those years overlapped with other work. After finishing his residency in Worcester, Yoav found himself without a studio, but he was offered an artist in residence/tutorial position at Harvard’s Eliot House, which had a shop in the basement. There he would mentor students from Harvard who wanted to learn woodworking He created a program of instruction and launched an annual furniture show, took students on field trips and invited fellow woodworkers and speakers, such as Tom Lie-Nielsen and Albert LeCoff, to give presentations. The affiliation with Harvard opened other doors; he was invited to write a blog for American Woodworker; he wrote articles for Woodwork magazine; he pursued his own furniture projects. This was toward the end of 2009.

For four years he also taught three-month stints in furniture design, sometimes with cardboard as the primary material, for college interior and industrial design programs in Israel.

Around 2010 he was accepted to an artist in residence program at Purchase College. It was a prestigious position that came with a studio, stipend, room and board in exchange for teaching one class and spending the rest of his time on his own work. He calls the experience “formidable” and says that during those four months he built his most important body of work to date.

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“Attn: John Everdell” is a campaign-style piece inspired by the form of a highboy. It incorporates salvaged boards from a packing crate addressed to Yoav’s mentor, John Everdell

 

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“Merritt,” assembled (Photo: Bill Hoo)

 

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“Merritt,” knocked down (Photo: Bill Hoo)

 

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“Ascent” (Photo: Bill Hoo)

Just as that residency was drawing to a close, he met James, a psychologist in private practice, who is now his partner. “James is also a wonderful bread maker, knitter and gardener,” Yoav adds.

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James, Asher and Yoav

When American Woodworker was bought by Popular Woodworking, Yoav met Megan Fitzpatrick. He’d been thinking about writing a book about building furniture with reclaimed wood; Megan was enthusiastic and had Scott Francis, her books editor, get in touch to discuss possibilities. “That was an affirmation by two people I appreciate,” he says. “If she thinks it’s a good idea, I will put the time into it.” He wanted the book to include work by others as well as his own – people from all over the world, in different disciplines. “The purpose is to let us pause a little and think, how can we utilize any sort of discarded material that has still so much potential? Sometimes the potential exceeds that of virgin-cut wood.”

Yoav spent two years working on the book, “Working with Reclaimed Wood,” which was published in 2018. By then he had made a home with James in the greater New York City region, adopted their son, Asher, who is now 5, and was working at his current job as a teacher of woodworking in the city. Ordinarily, he commutes four days a week.

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Yoav’s book. You can read a review here.

So here’s how Yoav faced his reality this past March.

He started with a process of elimination: What kind of woodworking-related activity can you do with your hands when you don’t have access to woodworking tools? He thought back to the design classes he’d taught in Israel, where students built pieces out of corrugated cardboard. It’s made from wood. It’s a readily available material – in fact, with so many parents confined to home and ordering products online instead of shopping in stores, there’s been an excess of cardboard to dispose of. And all you need to work with cardboard are scissors. (If you really want to go wild, Yoav adds, you could splurge on a $5 utility knife.)

His next challenge was to come up with a project that would be appropriate for each of the grades. He consulted the students’ other teachers. Fourth-graders were studying local geography; in Manhattan, that means skyscrapers. So Yoav decided to have his fourth-grade students make the Empire State Building. He found some plans of the building online, made a cutting list and templates, then sent the kit to parents to print out. Now the kids are making the building, right down to the spire and antenna. (You can read Yoav’s blog post about the project here.) He meets with students for half an hour a week via Zoom; sometimes he tutors individuals. “It’s such a shift in teaching,” he says, acknowledging the irony of the situation. “[Ordinarily] we say ‘No screens, no electronics!’”

The fifth-grade students are making animals – panthers, a dolphin, a penguin, a whale. Each student brings her or his own interpretation of the material to the project. For example, one wanted to sand the edges but had no sandpaper; she used her mother’s nail file instead.

Ninth-graders are tackling more complicated designs. They started with a box-jointed cardboard box. (Did you get that?) After that they moved on to furniture. Yoav has encouraged them to use notched designs, which can be elegant. Other designs involve layering the cardboard for stability. Origami, he notes, provides yet another way to think about using cardboard as a furniture-making material.

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Adapting to new circumstances. Whale, bear, Empire State Building and tools, including a laptop and camera.

As they near semester’s end, Yoav has been teaching the older students (and some of their parents, who couldn’t resist getting involved) to carve simple designs in basswood purchased online – decorative patterns, animals, letters – with a carving knife. Constantly thinking about how to keep them from cutting their fingers, Yoav recommended that they invest in mesh tape. “You sit in front of a camera,” he explains; “the student is miles away from you.”

Odds are, he’s inspiring a new generation of makers who will design and build innovative furnishings out of this abundant waste material, cardboard.

— Nancy Hiller, author of Making Things Work

True Grit: An Interview with Helen Welch of the London School of Furniture Making

Posted on by fitz
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Helen says this moody portrait, taken during a promotional shoot for a business bank, represents “the only time I’ve ever earned money for standing around doing very little.”

Chris Schwarz suggested I invite Helen Welch to be interviewed for the Lost Art Press blog. “She is a “[bleep]ing badass,” he wrote. “A tool nerd. Funny and sharp as hell.” So I wrote her by email. She sent back the following reply.

“If nothing else (other than saving lives), this lockdown has given us all a chance to do stuff we wouldn’t normally do. Things I’ve discovered during this time:

“I hate sourdough.

“I do not like to work from home. A one-bedroom apartment is no place to make the kind of mess I enjoy in the workshop.

“Practicing my golf swing indoors has aged the fixtures and fittings.

“The homemade wines I made two years ago are now drinking well. A rare case of serendipity.

“Danish is a very odd language but I’m enjoying the challenge.

“Videoing myself is a special kind of torture, only topped by having to edit the damn thing. Gruesome. Likewise Zoom, Skype etc.”

Then she said sure, she’d be happy to do the interview.

I knew I was going to enjoy our phone call.

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Helen with Mark Armstrong (center) and Sam Brown. “Sam teaches all the classes I don’t want to do, basically evenings and weekends,” Helen says. “Mark is a carpenter and friend of the school. He comes in to hang out because the school is his happy place. He’s also partially responsible for my tool collecting habit.”

Most woodworkers familiar with Helen know her through the London School of Furniture Making, which she founded and has operated since 2013. “It’s nowhere near as august as the London College of Furniture,” she laughs, acknowledging the similarity between the two names. Woodworking schools pride themselves on a range of qualities, from their size and diversity of course offerings to their cultivation of individual students’ skill in artistic design, or their faithfulness to particular historical traditions. The London School of Furniture Making is tiny, with just four benches, which allows Helen and her fellow instructor, Sam Brown, to give each student an extraordinary level of attention. Course offerings are varied in terms of topic and duration, aimed primarily at amateur makers. Short courses build specific skills; project courses offer opportunities to put them into practice. Beyond this, students can pay a daily fee to come in and simply use the benches and tools, as well as pick her brains. If the London School of Furniture Making were to claim a special niche, it might be that these characteristics make learning there unusually customized and accessible.

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Students from a three-day Core Skills – Joinery class last December. “As you can see,” notes Helen, “not everyone finishes their graduation project.”
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Helen’s parents, Michael and Leonora (with friendly pigeons)

Helen started the school after decades of work in the trades. She was born and raised in North London, where her father sold film (the kind for cameras in the pre-digital era) at Boots, a nationwide pharmacy chain. Her mother had a variety of jobs that included work in a perfume factory but spent most of her career in retail sales at John Lewis, one of Britain’s best loved department stories. Helen’s older brother, Maurice, is a passionate photographer who’s all about electronics and gadgets.

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Maurice and Helen

At the age of 11 Helen made a conscious decision to go to a girls’ school. “I didn’t want to have to fight for my teachers’ attention,” she explains. By the time she entered sixth form (senior high school in the United States), the school had become co-ed. In 1984, as she was preparing to take her A-Levels in biology, chemistry and business studies, she says, “all my fears about being overlooked came to fruition. I was simply exhausted from the struggle, so I left.”

Later that year she returned to the school to attend a careers fair, most of the offerings at which were “not interesting, just banks and boring things, not what I envisaged doing…” But as she wandered around the booths, a couple of people at a tiny stall in a corner called out “Come chat to us! If you’re not doing anything, why don’t you come and work in our woodwork-cum-training college?” Why not? she thought, and jumped right in.

The business was a collaboration of four people – two men and two women – who shared a shop in the north London area called Kentish Town. “Splinter Group was a training center which carried out woodworking jobs in the local community,” she told me. “I was paid £25 per week as part of the government’s Youth Training Scheme.” The shop was a large space with an eight-bench hand tool room and a separate machine shop, all on the first floor (which we in the States refer to as the second floor) of a Victorian-era light industrial building. The work entailed a mixture of teaching/learning and making. “If it was wood, they did it. They would bring their trainees on site as well as building in the shop.” While working there Helen made a set of stairs; a complicated play frame for a children’s play center; a table and shelves, and a toolbox for the tool set they gave her.  “I remember thinking it was quite a good mix of skills and different woodworking projects. It gave me an idea of what was possible — there are all sorts of things I can make with these skills.”

After about six months at this cooperative shop, Helen spent a year doing a variety of work, “including making some fake French antiques for a guy I met in a pub.” She worked in building maintenance for a local women’s center and ended up applying for an apprenticeship in carpentry and joinery with Camden Council, where she spent three years – one year in building maintenance and repairs; one year of renovation and restoration on jobsites; and one year in a joiner’s shop making windows and doors. She earned her City & Guilds Certificate in carpentry and joinery in the late 1980s, specializing in (of all things) building forms for cast concrete structures, a skill she hasn’t used since. As soon as she had the certificate, she left the council job. “’This is a three-year prison sentence which is now up,’” she remembers thinking – “three years of misogyny and racism. I have very few happy memories [of that time]. It was tiresome, but I worked hard to not let it scar me.”

Helen took a job as a building inspector for the Building Control Department in Camden and then Islington, where she worked for five years. As someone who had worked in the trades, she says, “I realized there was a split between the people who came in from university and those from the trades. I quickly made friends with the ex-carpenters and the ex-plumbers. We were more collaborative when working with the chippies (Brit-speak for carpenters) on site, whereas some of our colleagues just wanted to read the letter of the law. [The work of building inspectors] is more of a problem-solving exercise,” she says, alluding to the kind of considered and constructive approach that anyone in construction or remodeling appreciates. She sums up that experience as “five years of interesting developments in my understanding of construction and the legal side [of that business].” But in the end, she felt “I was too young to be trapped telling people what to do. I missed being back in the workshop making things.”

So she took herself off to the London Metropolitan University (formerly the London Guildhall University/London College of Furniture, and before that, Shoreditch Technical Institute) to study guitar making. “I had a fantastic three years there,” she says of that time, which allowed her to develop her skills at a far higher level. She graduated from the program thinking “Wow, this is amazing – and there’s absolutely no career in it!”

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Helen with the last guitar she made, about 15 years ago. “I keep thinking I’ll get around to making another…,” she says.

Being a determined individual in need of income, Helen started making built-ins and doing carpentry. She had no shop; she worked in people’s homes. “[It was] me, my van and tool kit. Me constructing things on site. It worked for a good number of years.” Her business came exclusively by word of mouth. Her customers were mostly married couples with a couple of kids, “quite well-paid people in their mid-30s who’d just bought their first proper house and wanted to have some built-in cupboards.”

She supported herself by means of this work, without a shop, for about 10 years, starting around 1994. She had a typical complement of trim carpentry tools: a portable Festool table saw (made up by fitting her track saw into a table), a jigsaw, planer, power tools, and used a couple of “trestles” (sawhorses) topped with a sheet of plywood for a bench. “Not a lot of hand tools,” she says, then throws in: “When I think about it now I wonder how did I manage to last 10 years doing that? Eight-by-four sheets of MDF. Hateful!”

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A set of living room built-ins typical of the work Helen did for ten years without a shop.

As a side gig ever since completing her training in lutherie she taught part time at London Metropolitan University, City and Islington College, Women’s Education in Building and The School of Stuff, to name a few – some evening classes, sometimes one day a week. She enjoyed teaching but she still had no intention of doing so in her own set-up.

Around 2004 Helen finally got a workshop in a space shared with a fellow who went by the name Bob Smoke (not his real name); he made props and designed special effects for film and television. Although she describes it as “an enormous hangar of a place which was freezing cold in winter and hot in summer, never comfortable,” the new work situation gave her the opportunity to retrieve her better equipment from the storage unit where she’d been keeping it, and to make more interesting things than painted built-ins. Jobs still came entirely through word of mouth.

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Oak sideboard, circa 2014, made for Helen’s friends David and Paul. She thinks this was the last commission she took on before closing down Welch Assembly, her cabinetmaking business.

By 2010 she’d decided it was time to commit to what she calls “a proper workshop.” She looked around. For £600 a month she could get a place that wasn’t much bigger than the living room in her apartment. But for £750 she could get something much better: a shared workspace in a complex of industrial warehouses built around the 1970s in Tottenham, North London, that’s home to 15 cabinetmaking businesses. She went to see the couple of guys who had the space to let, Alistair Williams and Joe Ridout – they run a furniture and cabinetmaking company – and she ended up renting the space. Since then, she says, “I really haven’t looked back.” When they moved into a bigger unit she asked if she could take on a couple of students as a new venture – “something sustainable that makes me feel like I’m having a good time…something that will not give me sleepless nights and leave me feeling resentful to[ward] customers.” She found that there were lots of people eager to learn, people who valued her flexible set-up. Her fledgling venture grew, and she decided it was going to be a school. Happily, Joe and Alistair were and still are very supportive.

Most students find her through the school’s website. Classes have been cancelled since mid-March. She’s spent her time at the shop alone streamlining things and improving ergonomics – much-needed improvements to what she calls the previous “controlled chaos,” while also “playing with my tool kit, as opposed to the school’s. I’m a tinkerer.” The last thing she made was a solid silver plane, just for fun. “I wanted to try my hand at jewelry, working with precious metal clay.” After firing you end up with 99 percent pure silver.

Most other businesses in the building have been carrying on as usual. For those doing custom furniture and cabinetmaking, there’s plenty of space to keep the recommended distance from others; for teaching detailed hand skills, not so much. She hopes to resume classes in June.

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Ash and fumed oak display cabinet for a school in Essex, circa 2011

— Nancy Hiller, author of Making Things Work