Carl Jensen

One of the most frequent questions that I’m asked about our company is how we deal with all the nails that come to us in the reclaimed wood that we buy. I usually answer by singing the praises of our de-nailing crew who work outdoors, year round, using metal detectors, chisels,  hammers and a custom tool that we call a “slide grip” to prepare material for the saws. But the reality is that, as good as our crew is, a few nails still find their way into our mill -and boy can they do a number on a saw blade! When a nail sneaks into the mill, the first place that it is likely to make itself know is at the Head Saw or Re-Saw. Anyone who has worked in the mill longer than a week will recognize the distinctive loud pop and snap of the band saw blade breaking. Most of us cringe at this sound but Carl Jensen smirks through his beard in delight. That’s because Carl is our full time blade-sharpener, chisel-grinder, chainsaw-tuner and master tinkerer. He’s got an arsenal of sharpened band saw blades in arms reach so that the saw will be up and running again before you can say “down time”.

Carl 8

Carl 9

 

 

 

 

 

 

 

 

 

The “slide grip” that I mentioned earlier: Carl invented it. He has also been fabricating them for us for nearly two decades. Just clamp the “slide grip” on that ‘ol rusted nail and a yank or two will bust it free from the gnarliest barn timber you can bring us.

 

slide grip

Band saw blade sharpener.

Band saw blade sharpener.

Tooth straightener.

Tooth straightener.

Pass through this door to enter Carl's workshop.

Pass through this door to enter Carl’s workshop.

Food for thought when sharpening.

Food for thought when sharpening.

These teeth are sharp.

These teeth have a bite!

Short and wide chisels and long and narrow chisels. A chisel for every occasion!

Short and wide chisels and long and narrow chisels. A chisel for every occasion!

Carl's custom stool.

Carl’s custom stool.

 

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Foundry Maple Reclaimed From American Crayon Company

The American Crayon Company’s factory in Sandusky, Ohio was slated for deconstruction, so we headed out to rescue the antique wooden bones of the building before it went to waste. We rescued 2 truckloads – that’s 24,000 board feet – of Foundry Maple. The old wood has endured thousands of footfalls, heavy machinery, and a smattering of colorful wax crayon materials.

Here’s a peek inside the former factory:

The American Crayon Factory in Sandusky, Ohio being deconstructed

The American Crayon Factory in Sandusky, Ohio being deconstructed

The factory’s history
When the first superintendent of Sandusky’s public schools wasn’t satisfied with the chunky chalks used on the boards in classrooms, he turned to his brother-in-law to create a new and improved chalk. William D. Curtis’ accepted the challenge and began experimenting in his kitchen in 1850 with what became, years later, the American Crayon Company. ACC became the largest employer in the area and produced many popular art products including crayons, chalk, watercolors, pencils, paste and cleaners.

Over the years, American Crayon acquired many other companies, most notably Prang Educational Company with their trademark Old Faithful geyser logo in 1913, and Dixon Ticonderoga who expanded their industrial supplies line in 1984. The former merger slowly outsourced the labor and plant operations to Canada and Mexico, sadly forcing the Sandusky plant to close in 2002.

crayon factory 2

 

 

The flooring’s next life

Bundle of Maple Foundry reclaimed from the American Crayon Factory

Bundle of Maple Foundry reclaimed from the American Crayon Factory

After leaving their old factory life behind in Ohio, the raw industrial salvaged Foundry Maple arrived at our eco-friendly shop in Upstate New York where we’re de-nailing and re-milling the planks into paneling, flooring, fixtures, and more to be used in commercial and residential spaces. Limited quantities are available and each ‘batch’ of this grade comes with one-of-a-kind often hard-earned texture, wear marks, and color.

Reclaimed Maple Goundry from the American Crayon Factory

Reclaimed Maple Foundry from the American Crayon Factory

Full of texture, and on occasion original paint, Foundry Maple can be put back into service with little or no finishing. Ranging from browns and golds to greys and occasional lavender tones, Foundry Maple offers unmatched color, original distressing, and character. While this reclaimed Foundry Maple may not be as boldly colorful as the products that passed through the factory, the boards continue to maintain a vibrant history and unmatched durability.

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A tour of reclaimed Chestnut Hill

Jered took a recent trip to Boston and stopped at Chestnut Hill mall to check out our reclaimed wood in its new home. Here’s what he found:

When you walk up to Anthropologie, you’re greeted by doors made of a mixture of Douglas fir and Cypress milled from wood reclaimed from wine vats. That same wood accents select areas of the store as flooring. Our sister company, NEWwoodworks, created a shelving unit made of reclaimed American Gothic Oak.

Anthropologie entrance with wine vat stock siding.

Anthropologie entrance with wine vat stock siding.

 

NWW AG Oak shelves

Anthropologie American Gothic Oak shelving.

Fir Cypress flooring

Anthropologie wine vat stock flooring.

Anthropologie wine vat stock flooring.

Anthropologie wine vat stock flooring.

Madewell features Character Select Heart Pine flooring that has no finishing on it, though some is painted white as part of their more recent designs.

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Character Select Heart Pine at Madewell.

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Character Select Heart Pine at Madewell.

Next up is Eileen Fisher, where the ladies working there told Jered they get lots of love for the floor. The flooring is Engineered American Gothic Elm which has been stained and refinished on site.

AG Elm

American Gothic Elm flooring.

The new Basset Store features FSC Certified Red Oak siding that has been heavily brushed and primed in our shop then finished in the field.

FSC Red Oak

FSC Certified Red Oak siding at Basset.

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FSC Certified Red Oak siding at Basset.

We’re excited to see our ‘old’ wood getting new life in Boston. Jered had a good time visiting (he said something about the best cannolis in the country?!) and is already gearing up to go back in late Fall. We’ll be sure to share more!

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Custom Ebony Finish; Work of Art

Goorin 4Here’s a quick snapshot of what’s passing through the hands of our finishing crew.

Goorin 3

Settlers’ Plank Oak with Custom Ebony Finish

SP Oak

Settlers’ Plank Oak unfinished

This custom ebony stain with matte water-based polyurethane gives our Settlers’ Plank Oak floor a more monochromatic appearance thereby drawing more attention to the variation in texture and grain.

Robert-Mapplethorpe-Louise-Nevelson-1986

Louise Nevelson

 

 

 

 

 

Kind of reminds me of a Louise Nevelson sculpture.

nevelson

Goorin 2

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