I Was Like a Fox in the Henhouse…

Today I took a day off of any duties and works and I went for a walk in the forest, with my camera. And right at the edge of the forest, I got distracted.

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I had planned a long picture-taking walk, about five-six kilometers. I had drink and snacks packed, an audiobook prepared, and just in case I find some mushrooms, I had two cloth shopping bags in my backpack. I thought maybe I find enough for a dinner.

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Boletes are growing in huge numbers. I did not even get to the best places and I filled both shopping bags before venturing so much as twenty-thirty meters into the forest. They weighed about five kilos each, here you can see them after I took a hefty portion off the top to give to my neighbor, who likes them, but, like my parents, is too old to go collecting herself.

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My tiny kitchen counter was covered in mushrooms. It took me about six hours to clean all these and cut them. Most were cut to slices to dry, but some were too soft and spongy (and there were some blushers in there too) and had to be cooked right away.  And even though there was a lot of waste, I still filled the whole vegetable dryer and a table with drying, and my biggest pot with cooking. There are good ten-twenty meals in the pot, so after it all cools down, they will be divided and packed into small portions and frozen.

I must apologize, I did not make any pretty pictures for you today. But I am really tired, despite my walk being only about one-fifth of the length I planned.

Oh My Potato!

There is a lot of talk about sustainability and growing your own food etcetera. So I wish to share this year’s results of our efforts in this regard, specifically potatoes.

In the spring we bought 20 kg of potatoes for about 40 € including shipping. We planted them to a patch approximately 40-50 square meters and now my father has great fun harvesting them.

Typical potatoes, ones that go into the cellar for storage look like this.

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Then there is also a lot of “beads” which are very small potatoes, and a lot of potatoes that are damaged by weeds, slugs, bugs etc. Those need to be consumed first. But this year it looks like we do get reasonable amount of big potatoes in good condition. And whilst the saying in Czech goes “Čím hloupější sedlák, tím větší brambory” (“The dafter the peasant, the bigger his potatoes”), I think that saying just reflects the enviousness in human nature. Because getting reasonably big potatoes, regularly, is not easy.

The main problem with potatoes is that they need light, humous soil, and the soil in our garden is more like heavy clay. In the vegetable patch, it is a lot better, because that soil is a result of careful cultivation over several decades of tilling the clay with compost, manure, wood ash, and fertilizer. Still, it is far from ideal and way too sticky. So this year I have tried to improve the soil further by adding a lot of organic material directly around the potatoes during planting, specifically crushed reed stalks from my sewage water treatment facility. It seems to have helped – a few plants were planted without the reed stalks and their potatoes were visibly smaller. Also, the soil with the crushed reed is easier to tilt and falls easier apart. So it seems I have a use for the reed stalks, which until now were a waste-product.

But even without those, each year when we grow potatoes, there are outliers like this ca. 500 g (>1 pound) specimen.

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Pieces like these bring great joy to my father, who currently really has fun with garden fork tilling the patch and getting the potatoes out. We have a small tractor, but my mother has urged me not to use it and leave my father to do the work manually – he needs the exercise and enjoys doing it. And although he impales some potatoes on the fork, the damage is smaller than the plow would do. For example, this 950 g specimen got impaled and needs to be eaten asap, but a plow would probably just cut it in half.

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Well, that one is really an outlier. It can feed the whole family for a day. It would be great if they were all like that, but that is alas unattainable.

Ok, enough bragging and back to the sustainability issue and soil care a bit.

We have planted circa 200 plants. We get at least 120 kg of potatoes from it, so on average 600 g from each plant. That means we could, theoretically, set aside 20 kg for next year and still have 100 kg to eat. So how does that help us re: self-sustainability? It is just about 600 g of potatoes per week per person in our household, so two-three servings. That is a lot, being a significant money saver. But it still does not bring us anywhere near to being self-reliant.

The first obstacle to that is of course the sheer amount of land needed for true self-reliance. I almost have the land, but the soil quality on most of it is very poor and it would take years of back-breaking work to bring it up to scratch with the vegetable patch.*

The second obstacle are nutrients. Potatoes have about the highest yield per area of all crops that I can grow here, but they also deplete the soil of nutrients really, really fast, and can destroy it. I do not need to go too far to see a real-life example of this – my neighbor does not make compost, does not take care of her vegetable patch the way we do, and she did grow potatoes always in the same spot for many years. The soil got sour, and the potatoes were getting so small it was not worth the effort anymore.

The third obstacle is pests and diseases. We solve this problem by twofold approach – we spray the potatoes against mold and beetles, and we only grow them every second year. It seems to work out well, but should we try to be self-reliant, it would double the needed land again. We alternate them with onions, pumpkins, and legumes, which also produce reasonable harvests, but nowhere near to be significant on the same amount of land. Alternating the crops also reduces the amount of pesticides we use, since onions and legumes do not need to be treated.

The fourth obstacle is the sheer amount of work needed. My father does most of it, with me only doing the most difficult parts like plowing, and it takes a lot of time and effort throughout the year. To feed all three of us that effort would be tenfold.

This makes me highly skeptical about growing your food on the windowsill or front porch. But even so, I think it is a great idea to plant some vegetables in pots on your windowsill or front porch if you can, just do not expect any wonders regarding the amount you will get.

What you can expect though, is great taste. Supermarket bought vegetables cannot hold a candle to anything you grow by yourself.

  • The poor soil quality around here is one of the main reasons why many fields were converted to pastures and meadows after the Iron Curtain has fallen.

Mowing Pictures – Part 1 – Butterflies

I made these last month and then I forgot to post them. Well, the pictures are not that good, they were made with my phone. But I still think they are worth posting.

When my neighbor has finally mown the meadows surrounding my house, he left a bit unmown just in front of the gate into my garden. He always does. I do not know why maybe he is afraid that he will damage the geodesic leveling pole that is positioned there. Regardless of his reasons, I have to mow that piece with a scythe, and this year I have made a few pictures of the various critters and flowers that live there whilst doing so.

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© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

Punch and Die (and Fun)

I do not have the genius of Leonard da Quirm, but I do share one trait with him – I get easily distracted and sometimes spend several days trying to shave off a few minutes of some task or save a few bucks. Sometimes the effort definitively pays off – as in the case of my belt grinder or my forge burner, sometimes it is a success but with a question mark whether it was worth it – like the unbender (now I know it was worth it, btw, I have used it several times already and it is time-saver), and sometimes it is a bit of a flop, as when building a vacuum pump. If I had a definitive fail, I do not remember it, and so I allowed myself to get distracted again these last two days.

I have a problem with making metal bolsters, handguards, end-caps, and pommels. As in, it is difficult to get material thick enough to make them pretty, and even if it were not difficult, the result would be overtly heavy and thus would put the knife balance totally out of whack. The proper way to make bolsters and end caps is to make them hollow, and there are techniques for that. One of them is forging – as I did in the rondel dagger project. But that is labor-intensive, has poor reproducibility, and requires special tools anyway. Or I could buy prefabricates and adjust my design(s) to fit what is already on the market. Screw that!

So I have decided to make some new tools, and test them. The inspiration was a technique of minting coins before the invention of fly screw-press, which I have seen as a child in some black and white movie which has shown the making of Prague groschen at Kutná Hora. I remember nothing else about the movie except the part where they strike a punch on a silver blank with a hammer and thus make a coin. I think there was some drama and history in there too…

First I have made a die out of 5 mm high-carbon tooling steel. It consists simply of two holes – one for the bolster and one for the end-cap  (I have chosen my small hunting knife as a pilot project because I think the design will be improved a lot by it and because I do plan to make more of these knives in the future). Second I have ground two punches out of square stock of high carbon tooling steel that I have scrounged at my previous job. Grinding the forms with angle grinder was not easy, but it was not insurmountably difficult either. I had actually a lot more trouble with welding onto it the 15 mm round stock for holding the punch in place and for striking – my welding sucks, bigly. And because at least the first strike needs to be real mighty, I have built a small wooden stand to hold the punch in place for that.

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With the assembly on the concrete floor, as you see it in the photo, I have given it a mighty whack with my puny Mjolnir. And I rejoiced because it was a success. To protect the floor from damage I have put it on a steel plate for subsequent tries and I went and punched four sets for the four blades that I have currently in making, three out of brass and one out of pakfong.

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The pakfong was a bit thicker than the brass so it gave me some grief, thus the surface is not so smooth on the end-cap – I had to whack it several times and it wandered off the die and I struck it without noticing it. But that should not be a problem, there is enough material in there to polish these dents out.

It took me mere minutes to punch all these, and after a long time, I was really, really happy for a bit. There are a few details to iron out – like making a better stand for the punch, making it so I can put it safely on my anvil, figuring out the ideal amount of overhang and so forth – but it functions as it is and it is a massive saving in time already. Whether the knives will really look better remains to be seen, but I am confident they will. Further, this opens a lot of new possibilities for knife designs for me.

I Probably Won’t Do This Again…

After a month of work, I am finally at a phase where I have something to show for it. The kitchen knives are in the tumbler for the second day now, tomorrow I shall check if they are ready or not. But it need not hurry, I have enough to work with – eight fully polished blades.

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Today I have etched the logos and numbers on these because it is easier to do on a naked blade than on a finished knife. Now I can finally work on finishing at least some of these into final products while the kitchen knives tumble.

Working in bulk does save significant time and even resources, but 18 blades in one go was a bit too much. I am going to reduce the batches to 8-12 in size. That way it should keep its savings, but the polishing hell will not be that long. Polishing is extremely onerous and unrewarding work because one keeps doing the same thing day after day, working through the row of belts with very slow progress. With one knife, it is one-two days of a boring slog. With eighteen knives, it was three weeks – and one of them got broke and nine only to 120 grit before going into the tumbler, if not for that, it would be even longer.

These are not perfect, some of them have serious problems regarding symmetry, although only in one case it is visible with the naked eye. On all of them is it visible with calipers. I am starting to doubt that I will ever do a good job, but there are some signs of progress. One of those signs has, unfortunately, a bit of a negative consequence on these blades, all 17 of them – they are a bit thicker than I expected (a few tenths of a mm). That is because I have gotten a bit better at working on the belt grinder and thus I did not grind away as much material as I used to by having to correct mistakes

Mind you, they all will cut perfectly fine even so, and some of them already do despite not being sharpened yet. But a thinner blade will always cut better. On the other hand, these should be extremely sturdy and should be able to withstand even some serious abuse, and that is a plus for a hunting knife. We will see if there will be people willing to pay for these without bashing me over the head afterward.

Now to think about how to dress-up these blades and the accompanying sheaths. I think I have quite a few more weeks of work ahead of me, but now it should be creative work, and therefore much more fun.

Well, It Sucks, But…

My goal in mcgyvering a vacuum pump was to remain under 100,-€ – which I did – and get better results than I have achieved with my shop-vac setup – which I did too. Still, I do not know whether to be disappointed or satisfied.

I wanted to utilize things that I already have, which includes several water pumps that are used to water bonsai trees and vegetable beds in summer and pumping water out of the cellar in the winter and some spare piping from house renovations. So I had to buy only the things for making the vacuum pump itself – in combination with a water pump, the best option seemed to be something based on the venturi principle.

So I went and bought these parts:

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The parts were connected to each other more or less in the order as they are laid out on the picture. The black plastic hose connector was fitted into the brass one to lower its inner diameter. The brass hose connector right next to the right side of the chrome T junction is the inlet nozzle – I have glued an old tip from a silicone sealant tube (not depicted) in it to get the position and size of the nozzle correct. Into the upper brass hose connector was glued the white plastic 6 mm hose connector for the air suction.

So water comes in the T-junction from the right, gets squeezed through a nozzle which sprays into a slightly bigger opening in the outlet left, behind which is again a big pipe. The spray drags with it the air surrounding the nozzle and that way achieves suction through the top of the T-junction.

I am not able to write-up complete how-to, but this is the final product up and running in a vat of water.

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The bubbles show it is working. When I connected the suction tube directly to a new vacuum manometer, I got a suction of whopping 0,6 bar, which did really impress me. Unfortunately, I do not get anywhere near that when I connect everything to the jar. After a few minutes, it stabilizes at this.

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0.22-0.25 bar is still a bit more than what the shop-vac could achieve (which was 0.2). So it is usable and it is a definitive improvement because unlike the shop-vac it can run non-stop with zero risks of overheating anything, and it also makes nearly no noise, so a win there too. But when it achieves this, it still bubbles, so it still draws air. And when I close both ball-valves on the lid (one ball-valve is for pressure release, one for the suction), I start losing pressure in the jar really quickly. That tells me that the jar is not properly sealed and this here is not the maximum this setup can achieve, but an equilibrium between the pump and the improper sealing.

I had to make a new lid from five layers of plywood for this, with two ball-valves and the manometer, so there was a lot of potential for failure. But I did use water/airtight plastic sealant for everything and I went over all connections once more, yet I still cannot identify the leak(s). If it was a pressurized container, I might find the leaks with help of soapy water looking for bubbles, but I do not know how to check vacuum tightness.

So this is where I am now and this is where I leave this be for a few days at least. It has occupied me for three days already, time to go back to making knives.

This Was Not Supposed to Happen – Quality Control and Salvage

The last batch of knives did come out of quench straight-ish, but the tangs were a bit crooked on some blades. No biggie, he said. Those are not hardened, he said. Will be corrected in a jiffy, he said. And then he broke a blade in half because he was an idiot.

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Still, I do not think the blade should have broken like this, it is tempered and I did not exert too much force. But maybe I did. Unfortunately, the tangs did partially harden on some blades, which is a major headache because I have to heat them up significantly in order to straighten them now. As my hardening experiment has shown, with this steel all that is supposed to be soft must not be heated above the 1050°C at any point in the process. Which, admittedly, I did not know for sure at the time of quenching these blades.

So what to do with this? I have spent nearly eighteen years being involved in quality control in one way or another, and I must say it is a great way to make enemies at all levels. Customers hate you for the crap your colleagues have produced, your colleagues hate you because you point out to them that they have produced crap and the management hates you because you cost them money (both when things go well as well when things go awry) without generating any profit whatsoever. And everybody expects you to tell them how they should solve the problems you found – despite that part being actually their job, with yours only being the pointing out of the problems.

Now I am my own quality control so at least now it really is my job to solve the occurring problems. For example, apart from this broken blade, one blade seemed to be softer near the tang. I have decided to continue work on it anyway and I established later on that it was only slight decarburization and the steel is sufficiently hard deeper under the surface. So far so good. But is there anything that can be done with this broken blade? Well, I surmised that yes, and I have decided to try some new things whilst doing it.

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The broken-off tip was long enough for me to grind small (9 cm) blade out of it with enough steel left for a short hidden tang. I have simply cut it with an angle grinder to the desired shape and then thinned, formed, and polished the blade on the belt grinder. The notches on the tang are there to allow for the epoxy to grab onto.

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I have made the handle from a piece of apple-root from a dead tree given to me by my neighbor. The bolster is from a coconut shell. The wood was partially rotten, so I have decided to try my hand at a new thing – stabilizing the wood with epoxy resin. And to utilize my resources meaningfully on this experiment, I went and cut some more wood, even more rotten, from a willow trunk that lay in the garden for years. It is full of holes, wood dust (AKA grub poop), fungal discolorations and it is extremely porous, it even crumbles in parts.

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I do not have a compressor or a proper vacuum pump, and I was unwilling to spend any money on them at this stage, the resin itself was pricey enough. So I tried my best with things I already have at hand and I came up with this.

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These are two huge thick-walled glass jars for canned fruit, with removable snap-on covers. They should withstand vacuum reasonably well. I have replaced the glass-covers with ones made from particleboard, with the joint and snap-on latch made from fencing wire around some screws.

The jar on the left has a ball-valve in the middle, with 6 mm tubing attached to it. The jar on the right has two 35 mm holes and one 6 mm hole in the middle. To the middle hole is attached the thin tube from the left jar, shop-vac is connected to one of the big holes and a swiveling cover is over the second hole.

I have given the knife with handle suspended in resin in the left jar. When the shop-vac was running with the ball-valve open and the big hole covered, it sucked air reasonably well out of both jars. But shop-vac cannot run with blocked intake for too long, thus the ball valve and the covered hole – after half a minute I could close the valve (keeping the low pressure for a few moments more), opened the big hole and left the shop-vac cool with flowing air for a minute or two. Then I have repeated this process as many times as it took until no bubbles were rising from the resin.

To get an estimate, I weighed the knife before and after, and it has gained about 20 g of weight (65 to 85 g), which seems reasonable, the wood was not extremely rotten, only slightly so. I have also weighed one of the willow pieces and the weight gain there was much more extreme – from ca 20g to 120 g. I have not cut the wood to see how deep the resin has penetrated, but it definitively penetrated deep enough to work on pre-formed handles, even if not on squared wood.

So this has confirmed that I can do this with the equipment I already have and that investing in some better equipment is thus warranted. Still, I am hesitant about spending 100,-€ or more on a vacuum pump, I hope I can mc-gyver something a lot cheaper. On Wednesday I am going shopping for parts. If I succeed, I will let you know.

Oh, and here is the finished knife.

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Overall length 20 cm, blade length 9 cm at the spine, 3,5 cm wide, satin finish (trizact A100). The handle was polished to 1200 grit and buffed with beeswax.

I have given the knife to my neighbor because she has refused payment for the dead tree and I think she should get something for such beautiful wood. She did not object this time and I hope it will serve her well.