.....Let me start with acknowledging Bob Teisberg of Ancientwood,LTD who introduced me to this beautiful ancient wood. And Earl Tharp, of Mammoth Hunter .... an accomplished flute maker who shared his working knowledge and vital techniques in working with this Ancient Wood of the ancestors.
My path working with some of the most incredible woods mother earth has to offer, lets me the opportunity to experience the magic in using such exotic woods as the Eastern Aromatic Red Cedar, Zebra Wood, Lace Wood, and Spanish Cedar. While making the first flute case I felt the need to design a vessel which would house an instrument of courting and love, an instrument of mysterious origins, an instrument used by Kokopelli, the hunchbacked flute player who, in the beginning assisted the clans in their treks as the grasshopper Mahu who, with his flute confronted the Eagle of the high mountains and gain permission for the people to settle in his country.
Using Red Cedar is significant as told in the story of the Thunderbird ... a mythical being that is revered by all clans who live in the plains. The Thunderbird is regarded as a rain bringer, as lighting flashes from its eyes and thunder is caused by the beating of its wings. The Thunderbirds live in the cedar forest at the western end of the world where they build their nests, wield cedar bats and stuff their pipes with cedar needles. For this cedar wood is linked with the Thunderbirds who, in a thunderstorm, emerge and creates the storm. The Eagle, bird of the sun, is regarded as the representative of the Thunderbird in this Earthly realm.
As I walk towards my modest shop, nestled among our cedar and pion trees, the cactus and ucka plants ... and out of sight by most... I enter into a world of meanings, stories, ancestors, pleasant and different wood smells, of lingering old saw dust, of neatly stacked lumber waiting to be crafted into a flute cases, a feather box perhaps, a medicine case comissioned by a revered medicine man, or maybe just a secret travel box to be born and given to an unsuspected young dancer who is striving to hold on to his traditions. I switch on the lights, gather kindling wood and fire up my old, but new to me potbelly stove. As the stove starts to heat, I decide the task for today and perhaps start by choosing the wood to be used...... you see I really don't size my projects to a uniform set of plans, Hmmmmm ... I don't have a single set of plans in the whole shop ! Rather, while selecting the wood, I determine the rough size by considering the wood at hand, its individual and particular grains patterns, and how I may use this wood in the best way ..... Ah... a good piece for a top, one here for the bottom, two similar pieces for the sides and ends ... Now ... let's make a flute case.
The Ancient Kauri Story
Ancient Kauri is derived from a number of buried prehistoric forests that grew at the dawn of time,some more that 50,000 years ago. These forests are located in the Southern Hemisphere on the Northern Island of New Zealand, north of Latitude 36South. Buried under peat swamps by an unexplained act of nature before the last Ice Age, the trees were left lying just beneath the surface of the ground. This underground resting place, sealed from air, became a perfectly balanced cocoon that preserved the timber. It is known to be the oldest workable timber in the world. Extraction of these logs is time-consuming, expensive and technically difficult, requiring skilled operators of heave machinery. Working in wet conditions,
logs must be carefully brought to the surface. Once removed from the ground, each log is assessed, then milled to yield the best grain and timber qualities. Ancient Kauri has a beautiful and distinctive grain. When polished, the wood is a deep golden color with hues, textures and sheens that change under differing shades of light
In my wildest dreams I never thought that today, I have the privilage to work with one of Mother Earths hidden secrets .... Kauri Timber ..
Grand father allowed me this honor, to aquire this ancient wood and I promise to uitilize this privilage to do good.
It is a natural fit to build a flute case using highly aromatic Eastern Red Cedar and this spaticular Kauri wood. Just gaze at this wood, consider the Red Cedar, you know in your heart that you must use no metal materials no varnishs,or polyurthine ..... only wood dowels, leather cousioned saddles, leather ties to secure your most presious flute and to finish your case with the highest grade of Danish Oil avalable.
Carving a Woolly Mammoth seemed to fit well with Kokopellie, the Eagle, the Ancient Bison and the guardian snake of the East called Tokchi'l
Those of you who would dare to explore the use of this majestic wood for your own creations.... I would like to introduce a thought, a kind and special piece written by a Master Flute Maker.
The Zen of Ancient Kauri ....... When one decides to work with a piece of Ancient Kauri Wood I suggest that you wait until the end of the working day when it is quiet. Lay the piece of wood on your work bench, light a couple of candles and dim the lights. Put on a piece of your favorite soothing music, sit back, and enjoy a cup of coffee or a glass of wine. Get use to working at this pace because this is how you will be working for awhile.
Ancient Kauri wood is not like any other wood you will ever work with When we say the wood has been unchanged be the ages we are stretching the truth just a little. Many changes have taken place which is why this wood must be handled differently from other woods. Carbon 14 is the process that is used to date the wood. As I understand it all living things take in Carbon 14 while they are alive, but as soon as they die the Carbon 14 begins to decay at a very steady rate. After about 50,000 years there is virtually no Carbon 14 remaining. Because we know the rate at which Carbon 14 decays we now have a method to date the object.
Much of the Ancient Kauri wood that has been dated has been found to have virtually no Carbon 14 remaining which means that the wood is 50,000 years old or older. During this time a lot of changes have taken place as well. It is a well established fact that the absence of oxygen, anaerobic bacteria begin to consume the starches within the cells of the wood,. This is one fact that contributed to the sound of the Stradivarius. This change has also happened to the Ancient Kauri wood. Another change that is important is that the resins in the wood have sort of fossilized into amber. Ancient Kauri amber is highly sought after and traded for making into jewelry. You might think of the Ancient Kauri as wood that is impregnated with amber and this is why you must GO SLOW .....
When you saw a piece of Ancient Kauri wood tour saw must be sharp, clean and stable. Even though the wood is very light in weight it is also tight in grand and impregnated with hardened resins or amber. Anything which causes the least amount of heat will cause the Ancient Kauri wood to begin to twist and bend. Recently a cabinet maker associate of mine sawed a piece of Kauri and he said is continued to move for about a week. If you want crooked wood, saw fast and heat it up. A band saw works great but a hand saw is even better. A high quality balanced blade with a zero clearance insert and a micro splitter also works satisfactorily. Remember..... any friction generated in sawing will warp the wood.
When you sand a piece of Ancient Kauri wood you must remember that it is very soft. I stay away from it with an electric sander. The heat can cause the wood to fuzz and the sander marks can be extremely difficult to remove. Remember the grain on this wood is not like regular but twists and turns in every conceivable fashion. I start with a course grit and gradually work my way down to 2,000 grit in 15 steps. After the 2,000 grit I soak the piece with couple coats of Danish Oil (allowing it to set about 20 minutes between coats ) then I wipe off the excess. After the oil hardens for at least 72 hours I sand again with 2,000 grit then apply 100% carnauba wax with a high speed floppy wheel followed by sheepskin buff. At this point the wood looks like very
finely powdered gold floating in a pool of liquid.
Turning an Ancient Kauri Wood flute is special for me. I use a high speed tool with a stone burr to burn the finger holes into the wood. This allows me to very finely adjust the tuning in a way not practical with a standard drill bit. When I tough the tool to the wood magic happens as a soft white smoke infuses the air. I am instantly transported back in time in much the same way that a scent from childhood returns me to those carefree days of my youth, but I am transported back thousands of years as if some vestige of my prehistoric ancestors remains in my DNA. The smell is a sweet, faint pine like fragrance that lingers in the air long after the turning is complete. I have learned to love the smell so much that I am now making incense from the sawdust and I plan to give a small packet of Ancient Kauri Wood incense with each flute I sell in the future.
When you are all done working with your Ancient Kauri, turn down the lights again, light the candles and enjoy another cup of coffee while you marvel at the beauty of this fantastic treasure ............. Earl Tharp of Mammoth Hunter
