One of the joys of researching the old ways of doing things is that every so often you encounter an amazing “new” way of accomplishing some task. Such is the case with the shoulder knife, an indispensable tool in the ateliers of Roubo’s world. The tool’s utility is remarkable, and I am still discovering new uses for it.
We all have our favorite shop knives; mine is a Swiss chip-carving tip that gets used in many ways. And – like you – I have tuned it exactly to my preferences. Yet, more and more I find myself reaching for the shoulder knife that I made at about the time this book project began.
One of the issues of knife work is balancing the power and control integral to its use. Typically one of the limitations is the amount of force you can bring to the cutting tip, and the precise control you can exert on it. The determining factor is often the amount of handle you can grab comfortably. In fact, that is why my favorite knife has a small blade but a comparatively large handle. Still, I am limited to having only one hand on the handle. A shoulder knife overcomes that because the handle extends all the way from the knife tip to, well, your shoulder. You can obtain great power and control because it allows you to grab its handle firmly with both hands and leverage it off your shoulder.
Fig. 2 The long handle of the shoulder knife allows immense control because you can grab it with both hands and brace its handle against your torso.
The shoulder knife has practically disappeared from the woodworker’s tool kit, and to my knowledge only one company supplies them commercially. Making one is fairly straightforward. Although it is a simple tool, mastering it is not so.
The first step in making a shoulder knife is to make a pattern so it fits exactly your upper body’s dimensions and posture relative to the work surface. You can make a template from something as simple and disposable as heavy cardboard. A good starting point is to simply grab a yardstick tip in your hands, drape the stick over your shoulder and make note of the measurement from the work surface to your shoulder. Mark this out on the cardboard, then draw an arc to mimic the curve of your shoulder. Cut this out and compare it to your own body. Revise it until the match is the one you want. I made perhaps a half-dozen patterns until I got what I wanted, and then I cut that pattern out of three or four layers of cardboard and bonded them together to make it sturdy enough so I could get a good feel for its shape and fit. Just to make sure, I made a final pattern out of a piece of 6/4 softwood.
I selected a piece of scrap walnut to make my first knife, and a slab of ancient oak for the second, which is a few inches longer than the first. I used disparate methods for building each.
I made the walnut knife from two pieces of 3/4″ stock laminated together to make setting the blade much easier – even though the final thickness was 1–1/8″. I traced my pattern on both pieces and cut out the shape of the handle. Using a knife and chisel, I excavated a void matching the shaft of a Swiss blade purchased at a woodworking store on the two inner faces that were to be glued together in the final assembly. When the fit was perfect, I glued the whole package together with hide glue, with the knife blade embedded in and protruding about 1″ from the long handle.
For the oak-handled knife, I started with a 6/4 slab, then traced and cut out the shape I wanted. When I was satisfied with the overall shape, I sliced it lengthwise on the band saw. Recycling an old chip-carving blade, I excavated a pocket for the knife haft, then temporarily tack-glued the two pieces back together to shape the handle. (This is unlike the first knife when I assembled the knife and then shaped it.)
Fig. 6 The completed shoulder knives. The walnut one is a little shorter than the oak. Each knife is designed to fit its user.
With spokeshaves and files I shaped the handle to my preference, inserted the blade and glued the whole thing back together with hot hide glue. After shaping the business ends and adding compression-fitting brass ferrules, I coated both handles with shellac and wax, made the leather blade guards and called them complete.
My skill at using the shoulder knife is growing, but it is not yet to the degree where it is second-nature. But classical marqueteurs probably used it about the way we would use a scalpel for cutting filigree in paper.
One of the main differences between the manner of creating marquetry between the way I did it for decades and the way that Roubo practiced the art has to do with the assembling the compositional elements into the background. I had previously always sawn them together in fairly typical tarsia a encastro technique, and frankly it is still the practice where I feel the most comfort. But for Roubo and his contemporaries, the elements were often set into the background by scribing the element’s outline into the background with a shoulder knife after the background had been glued to the substrate.
Fig. 9 While the shoulder knife allows great control, you first must develop the skill to harness that control in order to follow a line.
This is in great measure the definition of David Pye’s “workmanship of risk.” Careful examination of enough old pieces of marquetry will indeed reveal instances where the knife got away from the marqueter.
When translating Andre Roubo’s “l’Art du menuisier,” we debated converting all of his dimensions to U.S. Customary Units or metric. After some discussion, we decided to leave them as-is for the same reason that we tried to maintain Roubo’s writing voice. This is a work of the 18th century, and so we sought to keep it there.
Translating French inches from that period isn’t difficult. Roubo uses the units of “thumbs” and “lines.” A thumb is just slightly more than our modern inch — 1.066″. The thumb is further divided into 12 “lines.” Each line is equivalent to .088″ today. The French foot is 12.792″.
During the last few weeks we’ve received some pushback about the price for the deluxe edition. It’s $550, which includes domestic shipping (international shipping is extra).
I know this seems a lot for a book on woodworking when birdhouse books can be had for $20. Here is our perspective on the price.
We wanted to offer the book, which represents thousands of hours of work during the last 10 years, in a variety of ways so everyone can benefit from it. You can buy a pdf of the book for $27.50. It has all of the information contained in the other editions of the book. The standard edition of the book is $57, which we think is a bargain for what you get. This standard edition is 472 pages, printed in the United States, the binding is sewn for long-term durability and the paper is bright and thick.
Finally, there is the deluxe edition. We are printing only 1,000 copies of this edition. It is offered in the original 11” x 17” size – same as the original Roubo books from 1774. This deluxe edition is printed to the absolute highest standards using the best materials we could find.
And yes, it’s $550.
For a book collector, that is a laughably low price. Vintage books (and high-end modern editions) that are $550 are at the low end of the spectrum. I gladly paid $2,000 for a vintage copy of Felebien (in French). And I routinely spend $500 to $1,000 for 19th-century books from England on carpentry and joinery for the Lost Art Press reference library.
What John and I sought to do with this book is give you a “period rush” – an inexpensive look at what high-end publishing is like. We both had that rush in 2013 when we received our copies of the first deluxe edition of “Roubo on Marquetry.”
When the truck dropped off the copies at John’s house in Fishers, Ind., we slashed open a box and each pulled out a copy. We each slid it out of the slipcase and then opened it. For the next 30 minutes we gaped at the copies in John’s garage. Honestly, unless you are a book collector, this book is unlike anything you’ve seen.
I know the above sounds like a hard sell. It’s not. We’ve sold only about 30 percent of the press run. So we’re going to have this book on hand for the next few years. If you can’t afford it now, maybe you can afford it after you sell that extra spleen you have hanging around.
But mostly, we’re just happy that we were able to offer this sort of book. Maybe it will take another year for us to break even on the project. That’s OK. But I know that everyone who buys this book will get more than they bargained for – from the authors, the publishers, the designer, the pre-production staff and the printers and binders on the front line.
If you have never seen one of our deluxe versions of “To Make as Perfectly as Possible: Roubo on Marquetry,” this tour will give you a small taste of the scale of the book and the quality of its components.
Since the release of this book (it’s long since sold out), people have come by the storefront or to shows to see a copy and it’s always a treat to see their reaction. First, they are amazed at the size – 12-1/4” wide x 17-1/4” tall. It’s uncommon to see a book of this size outside of a library’s rare book room.
But my favorite part is when they open the book. The printing and detail is so crisp that no matter how close you get, it holds up.
Oh, and the A.J. Roubo translations themselves are an incredibly important piece of woodworking history. Roubo’s “l’art d’Menuisier” is still the legal yardstick in many countries for what is good workmanship. And this is the first time his sections on furniture are being printed in English.
On Wednesday at noon we will begin taking pre-publication orders for the deluxe version of “With All the Precision Possible: Roubo on Furniture.” Full details on the book are available here. We are printing 1,000 copies, which will ship this summer.
Also, I neglected to mention that everyone who purchases a deluxe copy of the book will receive a pdf download of the standard edition. It will be delivered after you checkout.
Don Williams says his love of learning was probably fostered by the fact that his father was going through seminary when he was a child. Don grew up in a household without television. Instead, his family listened to classical music and read.
“But much to my parents’ dismay, I veered off into jazz as my primary interest, so they were pretty much convinced in my teenage years that they had picked up the wrong kid in the hospital,” he says.
Don maintains a love of jazz.
Jazz can loosely be defined as a combination of polyphony, syncopation and improvisation — simultaneous but independent melodic lines playing at the same time with unexpected and off-beat rhythms achieved extemporaneously. For Williams, jazz is not only what he listens to, still to this day, but serves as an outline for how he lives his life.
A self-proclaimed conservator, educator, scholar and all-around inquisitive guy, Don was a curious child who delved deep into varying topics – some unexpected – and from a young age, found connections.
“I think that being interested in many things, not everything, but many things allowed me to gather a lot of information,” he says. “And since I didn’t necessarily accept the rubric of the classroom, I think I’m able to see connections between distinct bodies of knowledge that wouldn’t necessarily be apparent if you were stuck in the tyranny of specialized knowledge.”
Don believes that the whole notion of specialized knowledge is a modern thing. “In the past, our predecessors in much earlier generations saw knowledge as the continuum rather than a series of cubbyholes,” he says. He mentions Robert A. Heinlein, who famously wrote:
A human being should be able to change a diaper, plan an invasion, butcher a hog, conn a ship, design a building, write a sonnet, balance accounts, build a wall, set a bone, comfort the dying, take orders, give orders, cooperate, act alone, solve equations, analyze a new problem, pitch manure, program a computer, cook a tasty meal, fight efficiently, die gallantly. Specialization is for insects.
Don believes pluralism and knowledge to be good things. “That’s part of why I was able to study lots of different things, both formally and informally, and manage to synthesize them into some body of working knowledge,” he says. “It doesn’t necessarily [make me] an expert at anything, but it does make adaptable I think.”
But expert, he is. In many things.
Williams spent his early years in southern Minnesota, and his adolescent and post-adolescent years in South Florida. His mother was an office worker, his father a pastor. Williams is the fourth child out of five.
At that time there was a program in Florida called the Faculty Scholars program that pinpointed high-achieving students on factors outside of grade point average. Williams had his high school guidance counselor convinced he was a solid “B” student.
“And then when the senior standardized placement test results came back, she literally left her office, came and dragged me out of class and read me the riot act,” Don says. He had received the second highest score in his very large high school.
This test result, through the Faculty Scholars program, allowed Don to begin college as a junior. He enrolled at Florida Atlantic University planning to double major in economics and political science. “This was 1972 and everybody was pre-law in 1972,” he says.
Improvisation
Around this time Don was working in the finishing room of the now-closed Schindler & Son, then a well-known restoration shop in West Palm Beach, Fla. “I found my attraction and interest at the workbench,” he says. “[The work there] was so much greater than the stuff I was studying in college that I dropped out of college around the beginning of my senior year. It just didn’t pull my fascination.”
Don began working full time for Schindler in 1974, and there met Nick Hlopoff, an internationally renowned decorative art conservator. “He was an exotic figure to me,” Don says. “Being a kid of the Midwest, Baptist parentage, here was this fellow who was an ethnic Russian, born and raised in Paris, trained by his father to care for artworks of exquisite importance.”
Nick, who lived outside of Detroit, would come into town and use shop space to care for the artworks of one of Schindler’s clients. “He was the guy who introduced me to the world of museum conservation as a livelihood,” Don says.
So Don decided to go back to college. “I still didn’t know precisely the path to art conservation as a career so I did the closest thing I could find which was to go to the University of Florida and major in architectural historic preservation.” But a year and a half in, the university changed its curriculum in a direction Don didn’t like. So he left school again.
Don worked in restoration and reproductions at Colonial Woodworking in Archer, Fla., and then in 1978 got a job at Maddox Foundry and Machine Works. “I worked as a patternmaker, which is ultra-precise woodworking,” he says. “I mean, ultra-precise.”
At Schindler’s, Don learned all about historical furniture, having worked on thousands of old-money European and French furniture pieces for wealthy clients in Palm Beach. At Maddox, he learned all about precision woodworking.
Polyphony
It’s the early 1980s now, and Don has married Carolyn, who he met on a blind date at his sister’s house. Carolyn wanted to pursue graduate work, and Don wanted to pursue art conservation. So they chose the southern most of the four colleges in North America that offered both — University of Delaware. Don enrolled in an undergraduate art conservation program, which was an interdisciplinary triple major of studio art, chemistry and art history. “Those are the very disparate disciplines that are the foundation for art conservation,” he says. “It’s fully left brain and right brain, both evolving simultaneously.”
There were 17 incoming students in Don’s program, but by the end of the first semester of the second year, Don was the only one left. “For most people either the hard science is going to weed you out or the fine art is going to weed you out,” he says.
A semester shy of graduating, he received three job offers in the museum field.
“I accepted the job offer from the Smithsonian with the promise that I would finish my studies and get my degree.” He did. It took him another year and a half of commuting one day a week to Delaware and back, but in 1985 he earned a B.A. in “Technology of Artistic and Historic Objects.” (The degree is now, more simply called “Art Conservation.”) Don was the program’s first graduate.
One of the ironies of the Smithsonian gig was that Don was hired in part to be on a team that was developing an art conservation graduate degree program, even though he hadn’t received a graduate degree himself. “So my time for the first couple of years was split between working on the curriculum for this new master’s degree program and doing hands-on caretaking and inquiries and research into the materials and artifacts that related to the Smithsonian.”
Don was 29 when the Smithsonian offered him a job. “You pinch yourself,” he says. “You just can’t believe it.” In his later years, when working alongside his best work friend, Melvin Wachowiak (“With All the Precision Possible: Roubo on Furniture” is dedicated to him), Don says they would often say to each other how unbelievable it was that they were being paid to do this type of work. “Because it was so much fun,” Don says.
Don describes the small group he worked with as semi-autonomous, with a think-tank-like culture. “We were given just extraordinary latitudes in pursuing the intersection of our interests and Smithsonian collection needs,” he says. His official job description, which he wrote, was 15 pages long. When asked to distill that down he says this: Be productively curious.
He was. And he was good at it.
“Part of my success in this poly-dimensional disciplinary world was that I could synthesize information from completely unconnected sources,” he says. “I hope I’m not bragging about it but it’s just a way, it’s a familiarity with the way I work. My wife has identified me as severely ADD so that’s perhaps worked out well there.”
A cabinet by the French-born 19th century New York cabinetmaker Alexander Roux.
Don’s restoration is on display in Washington DC.
Day to day, Don said he got to “literally intrude into the fabric of some of the most prominent artifacts in the history of the nation. And so some days I was working on irreplaceable treasures, and some days I was just sitting and reading. And still, the paycheck showed up at 12:01 a.m. every other Tuesday morning.”
The pieces that most interested Don during his time at the Smithsonian weren’t those with historical prominence but rather those that had “attractable degradation.” He talks about a 19th-century replica of a 17th-century French desk with spectacularly decorated marquetry but was run-of-the-mill in the 19th century.
“But it was in the Smithsonian collection,” he says. “And it was undergoing really catastrophic damage because the carcass underneath it – the veneer was coming apart. Working on that was really an amazing experience. But it wasn’t owned by anyone important. It wasn’t made by anyone important. It was a typical sort of French replica that an industrialist of the gilded age would have in their sitting room or library to kind of evoke a false nobility.”
Don also worked on a desk that was one of the earliest and largest examples of artificial tortoise shell. “I’m nuts about tortoise shell,” he says. “I’ve invented a really persuasive imitation tortoise shell for my own work so studying that piece was really great.”
The Mace of the United States House of Representatives
During the second half of Don’s career he was very much involved in the caretaking of the Mace of the United States House of Representatives (look it up on Wikipedia). “Most people don’t know about it, but it is one of the biggies, it’s right up there with the Liberty Bell,” he says. “For me, that was a such a powerful, powerful artifact symbol for us as a nation. And that has touched me to this day.” For 20 minutes Don’s work on the Mace was featured in a C-SPAN documentary called “The Capitol.” (The next time you watch C-SPAN, and they offer a panoramic view of the House Chamber in the Capitol Building, you’ll see the Mace at the very left edge of your screen.)
After more than 25 years of service to the Smithsonian, Don left his job on the last day of the last pay period of 2012. “I was ready,” he says. Don describes the Smithsonian as a scientific arts bureaucracy wrapped inside an academic bureaucracy wrapped inside a federal bureaucracy. “For us, geological timeframes were not merely some abstract idea, that’s how things worked sometimes,” he says. “It was pretty clear that my own particular interests no longer coincided with the organization that I worked for. That’s not malevolence or anything else. People’s priorities change. My priorities stayed pretty much the same, my organization’s priorities changed. They offered me the chance to retire at the age of 57 with lots of years of woodworking left and I said, ‘Wow. That’s pretty good.’”
Michele and Don at work on Roubo.
Don studying the tool cabinet of Henry O. Studley.
By now Don and Michele Pietryka-Pagán had already begun working on “To Make as Perfectly as Possible: Roubo on Marquetry.” And Don had begun work on “Virtuoso: The Tool Cabinet and Workbench of Henry O. Studley.” The Smithsonian (which demands right of first refusal on all intellectual property relative to your job when employed) had no interest in either. So he already had two projects dialed in that he knew were of interest to Lost Art Press. “I already had a working relationship with Chris and he was very much interested in the kind of scholarship I was trying to pursue,” Don says. “So really, Lost Art Press was a big part of my decision-making for this fairly substantial lifestyle change because frankly, it was a really, really good job. It was way too much fun, part of it, and paid way too much, but somebody had to have that job and it might as well have been me.”
So Don and Carolyn left Washington for a new life on a secluded property in the mountains of Virginia, which they had purchased a dozen years before.
Syncopation
These days, Don follows his muse. On the day we spoke he had plans to finish formatting photos for an article he wrote for Popular Woodworking Magazine. Then, lunch. “One of the advantages of me being here is that there’s always a fresh, hot lunch – every day. I’ll come down the hill and my wife will have made us a wonderful, wonderful lunch.” In the afternoon he’ll continue work on replicating a desk for a client.
He does a lot of writing. In addition to his woodworking-related writing he says he also has a “fairly vigorous email circle of circumstantial and political and economic commentary that I carry on with my virtual community of observers.” He also writes fiction – thrillers, specifically. His latest is about a museum conservator who has withdrawn to the mountains and gets drawn into a mystery dealing with documents hidden in a piece of furniture. Those documents threaten the structure of Western civilization, and the bodies start piling up.
“My wife says I like to do it because I get to put words in everyone’s mouth,” he says, laughing.
Often, while drifting off to sleep, Don says he’ll compose things in his mind — an artistic design, an essay on the state of the civilization, theological apologetics.
“One of the things that I celebrate the most is that I do not have to regimen my life,” he says. “It’s fairly mercurial. To be utterly frank about it I’ve reach a position of status in the artifact world that you know clients are willing to wait for whatever it is that I do.” (A recent call with once such client resulted in a request to call back after Christmas 2018.) “And I never for a moment take for granted that blessing. I’ve been restoring furniture and decorative objects with some level of accomplishment now since 1971. So that’s a fair amount of time.”
While Don says certain kinds of problem-solving skills are innate to him, he says his success is due, in part, to some marginal native artistic talent. “And I do mean marginal,” he says. “But through skill you can overcome limitations and challenges. Because skill is about repetition. It’s like in writing. The more you understand the meaning, the power, the organization of the words, the greater facility you have using those words for their intended purpose. And when you’re talking about working with artifacts it helps to be interested in and able to comprehend the nature of the materials from whence they are fabricated, the technologies by which they are fabricated and then the trajectory of their degradation. And I guess the thing that I am every thankful for is that I, for reasons unknown to me, can sort of put those pieces together. I’m not sure if that’s a talent or a skill or something else, but it’s something that I just sort of get.”
And frankly, he says, he loves being intimately associated with beautiful things. And not just aesthetic beauty. “Sometimes just thinking skillfully or thinking clearly or thinking creatively is a beautiful thing,” he says. “I love a beautifully crafted concept.” He says his daily expenditure of resources, time and energy spent on restoration is diminishing, “in part because there are other new avenues of rediscovering historical craftsmanship. The related expression is much more prominent on my horizon than before.”
Note Don’s toothing plane collection.
Don’s ideal week is not a whole lot different than what he’s doing now. He hopes to make more replicas of prominent, historic, smaller-scale furniture. He hopes to continue working for a very few number of clients whose collections he has a strong affection for (think: caring for tortoise shell). He has a series of sketchbooks, and the drawings in them are a car wreck between James Krenov’s car and André-Jacob Roubo’s car (his words). “I’m trying to apply some of the technology and artistic vocabulary of Roubo with the technology and artistic vocabulary of Krenov with a dash or two of some 16th-century Chinese furniture in there.” He likes writing. He likes collecting. He likes communicating. He doesn’t like traveling. For Don, a 50-50 mix of studio time and time spent at the keyboard is a good mix.
“I would just like to continue what I’m doing both artistically and intellectually and stay healthy,” he says. “I’m going to be 62 coming up. I just returned from Florida where we celebrated my mom’s 100th birthday, so I figure I have about 40 good years of woodworking left so I want to be careful so I can do it.”
Don and Carolyn live in the least populous county east of the Mississippi. Folks keep up with him online at donsbarn.com. The Barn on White Run, a three-story 19th century barn he found on eBay, houses his studio, classroom, library and dorm space. It took several years to dismantle, move and rebuild the barn, but for Don, it’s a dream fulfilled, a dream he’s had since he was a teenager.
Don enjoys the solitude of rural living. Since he was a child he’s sought out remoteness and isolation. “If I have an mp3 player, that’s about all the human contact I need most days,” he says. “I love being out here. It is exceedingly remote.”
At least four times a year Don and Carolyn head over the mountains to Charlottesville, Va., where he visits University of Virgina’s ophthalmology department for some issues with his eyes. They make a day of it, eating a nice lunch and stocking up at Trader Joe’s and Costco. He also relies on online shopping, and says he’s learned to appreciate “the astounding sophistication of the economy and its distribution network.” Most items arrive in 48 hours.
“You know, I’m just at traditional guy pursuing my faith and my family out in the mountains here,” Don says. “I have daughters who I love to death and a wife who I’ve been married to for 35 years, hopefully we’re on our way to forever, but that’s pretty much it.”
Except, it’s not. His life is an eclectic mixture of conservation, restoration, woodworking, finishing, metal casting, collecting obscure books, tools and shellac (yes, really), writing, gardening, presenting, discussing politics and making connections between all of it while forever remaining curious. All while listening to podcast lectures. Or, of course, jazz.
The opportunity to be listed as a subscriber in the deluxe version of “
