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The edge isn't good if the iron isn't sharpened.
This is YANAGI-BOUCYOU(Willow kitchen knife). We are going to temper it,
then grind it. Mostly, we do the tempering and we have the grinding done
by the place called Oosaka's Sakai. (Do you still use the old method of
producing?) Yes. (The trend of the sword smith?) Yes, aha. We have been
sword smiths since the old times. But during the Meiji era, because of the
Restoration, the samurais closed their business. All. Then, the swords didn't
sell anymore. That's why we converted to making carpenter's tools. (To making
planes?) Yes. So, it's been almost 130 years for the planes. Then, the planes
started to not sell well, so we started making these kind of kitchen knives.
This one is still new. It's been about 12,3 years. (What is the characteristic
of the plane?) Even if the wood is very hard, with a comma, the shaving
scraps are less than one tenth. (What comma?) One tenth of 1mm. (I saw a
very thin scrap at the joiner.) Yes. If the scraps don't become that thin,
the article doesn't fit perfectly in place. So, we temper the tip of the
edge, the iron can be shaved. ( Shave the iron?) Yup. The edge isn't good
if the iron isn't sharpened. If it doesn't work with iron, it will not work
with wood. Basically this is because wood is stiffer than iron.
I shrunk 4cm because I got old.After all, blacksmith is physical work. (Need strength for this job?) As you age, you lose strength. This is steel, the one I just placed there. Then, we hammer them.......Watch out for the sparks........ If you do that, it will stick. It will never separate. It has boric sand and boric acid and iron powder in it. That will melt together when fired around the temperature of 880C. Then, since they are hammered, they stick together. It's easy to say it, but when you actually do it, the steel doesn't stick. Many young people came to our place, but none of them actually became professional. This kind of work depends on each instance. That is why it doesn't work. It will be a different story if you can take your time, but this it is a matter of seconds. Have you interviewed other places, too? (It's the first time with a blacksmith.) You see we're different from other craftsmen? You need strength. I mean, I shrunk 4cm because I got old. I had 1m14cm around my bust when I was young, but less than 10cm now. For this job, it's no use if you don't have strength. My uncle, my mother's brother, was third in the regiment, in size. Don't know the regiment? Do you remember the pro wrestler by the name of Sakaguchi? He had that body. If I too grew up on better food..... 
I'm the 11th generation since the period of sword smith.(Have you been here all the time?) We started using these kinds of machinery from my father's generation which was 1940. We made about 50 edges a day with a crowd. When the machinery was damaged by the war, my father and I tried to file them, but it didn't work. There was another fire damage from the war. That was the night of May 23rd raid attack in 1945. (Where at?) Ebisu. The area was all burnt out, and you could see the trains come in from far. I worked at Ebisu till July 31, 1995. Then I came here (Koyama). You can't do a job like this in Ebisu anymore. That was a semi-industrialized area. We could use extremely large machinery there. Since that place was built on solid rock, the anvil didn't loosen. This place is nice too, but I don't know about it in 10 to 15 years from now. We hit pretty hard. I'm working with my son right now. (How many generation?) I'm the 11th generation since the period of sword smith. But there were several people before that. So, I'm not quite sure. I should be the 11th counting from the person who made the sword for Yoshimune(shogun) . That was during the Kyouhou (In the 18th century). And there was some before that and before that. It is told that the sword displayed in the Ueno museum is from the mid- Muromachi period, so that will be over 450 years. I can't relate to such old events. I only lived the Shouwa and Heisei era. But these techniques are continuously passed down and are still here with us. (Did you bring all the tools from Ebisu?) No, we replaced everything with new ones. The only thing we brought is that and this machine. We got rid of the rest. These machines are useless once they are taken apart. All these machines are produced in the downtown factory. (The floor is dirt?) Yes. It doesn't work unless the floor is dirt. With concrete, when the burning hot red iron is thrown on the ground, it cracks.  They
have at least 3 types of our planes.I think I have 12 to 13 years left to do this job. I was thinking my son would take over, but ever since the onsumption tax was added, the business is in a slump. It used to sell a lot before tax was added. After the tax, the sales dropped all of a sudden. We couldn't sell much anywhere, not even at a department store. Not that I really care much about selling. (You like the producing part?) Yes, it's fun. (Do you sell them directly to other craftsmen?) No, most of the planes are sold through wholesale dealer. (Those are planes for carpenters?) Yes, for professionals. (Is it necessary to change planes depending on the type of wood to grind?) Yes. That is why craftsmen have at least 3 types of our planes. They use the plane that brings out the most shine for the particular wood when shaved. This iron was refined in Europe during the 1850's. This iron was refined in Europe during the 1850's. The ones here are made in Germany. Their purity is good. (You use that?) Yup. (Is it no good without a good purity?) We have to examine it carefully or the scraps will not be as thin as one tenth of a millimeter. (Is it okay for the materials to be rusted?) Yes, it's fine. (Would new iron do?) No, not new. (Are there any marketplace for old iron?) No, there isn't any. They come to me. They tell me the year the building or the bridges was built, then I go see it myself. (To places like Germany and America?) Oh no, in Japan. It only takes me one glance to know from the color of the iron. You have to be able to judge iron like those experts on TV. (Do you use new iron for kitchen knives?) They are made with iron that can not be used to make planes. (How about kitchen knives made in other places?) Oh, those I think are made with modern iron, those knives that rust. (If you go to a joiner, are there many types of planes?) Yes, from small size to large size. (Do you make all the sizes?) Yes, if I am asked, I usually make any plane. Have you seen the ones with the blade this narrow, like this? I even make those. Those are made by putting the steel with the iron and heating it, then when it turns red, it is placed in the machine and cut in to small pieces. After that, each is finished. If the width is bigger than 3.03cm, it is better to make it one by one, but if it's smaller than that, it is faster if we cut it. (Can you cut them pretty fast?) Yes, after it turns red. It can be cut as easy as cutting the sweet bean jelly. We throw it away if it's not good, becomes a waste. (Which part of the process is a matter of seconds?) Lets see, umm, the part when it turns red and hit with a hammer. The red iron is placed on the anvil under the hammer right? It is decided at the moment when the hammer hits the iron whether it becomes an article or a waste. (You can't redo?) Nope. If it it's not good, it's a waste. That is why we have to be careful not to do it again. (Is then training hard?) Yes. We have to practice determined to waste a lot of materials. (Several young workers failed?) Yes. The worst case was when a young one wasted a montain of iron powder that would almost fill a 2 ton truck. He didn't succeed in the end. The fire didn't become this fine color of red. If the temperature is just a bit over, the steel falls apart. You see that on top? The thin plate of iron, that's the steel, but it falls apart. And if the temperature is lower on the other hand, they don't stick together. (Look to the fire?) Yes, it depends on the ability to observe the fire. 
We made sickles, kitchen knives, and hatchet and
took them to agricultural villages.(How old is your son?) 34, but... (But?) Well, it's very difficult. Maybe I would be as laid-back as he is if I was bornin his generation. In that burnt area, with nothing to eat, with no sabers to produce, I fixed the machines with my father, but there was no electricity. Using a hammer, we made sickles, kitchen knives, and hatchet and took them to agricultural villages trying to live through. (Craftsman had things to sell so they were okay?) Sales men had their wives' kimonos and such to sell. ('Onion-skin' living?) Yes. And there is nothing more miserable than living without food. (But is it so painful to look back at those times?) (Wife) Yes, I agree. Now it is not as fun as before. I mean it is harder to maintain business and make money right now. Especially ever since the consumption tax was added I hate to be in the position to be ordered. I don't mind talking face to face like this, but I hate being in a group. (With someone gossiping about?) Yeah, I just wanna yell, "Shut up! Who cares!" (Wife) He has been making things alone. (Master) With 7 or 8 craftsmen and if I am in a position to instruct like, "You do this, do this part like this " I don't mind. I hate to be in the position to be ordered. I was like that from childhood. You understand what I'm saying, right? Oops, I shouldn't say "Ore." I have to say, "Asshi." My father was always saying that. All the kids are happy when their fathers pass away. Finally the fussy, nagging, faultfinding guy is gone. (Wife) He is saying that because he is exactly like that. (Master) After my father passed away, I remember my mother saying that she was relieved. While he was alive, my mother worked hard on acting like a good wife, but after he was dead, that didn't matter anymore. (How about you?) (Wife) I really can't understand him. I think we are an unusual couple. Our personalities are exactly the opposite. (Are you okay with associating with others?) I'm okay. I'm the business. (Then aren't you two a good combination?) I'm surprised that we came this far regardless to how different we are. (Every married couple say that.) Is that so? (That is why many people get divorced right after the husband retires.) I can't understand that either. (It's because they have so much stress from everyday life.) Well, I'm with him everyday aren't I? (Master) And on the other hand, the husband feels like he is working and putting food on the table. That belief probably causes the many divorces after retirement. They should both work for each other. You cook the food and I earn the money, and we do well with the money. (Wife) You think that way about me? (It's like a TV program!!) (Master) But having this kind of job is really fun. You don't think about anything else. Just do this. (It's better if it sells?) Yes. Basically to make things is like that. Sell one computer, sell one tank. (All craftsmen say that they are not earning much, but they all seem happy.) Yes. Kitchen knives used for fishes are made the way planes are made. (Don't craftsmen directly order?) No, they go buy at the tool shops. (They see your carving signature there?) (Wife) Yes. (Do you ask other places for the planes' holder and the kitchen knives' haft?) (Master) I get the holder from the holder shop. For the kitchen knives' haft, we use the hafts that the hafter makes for us. (What about the box for the flakes of dried bonito?) The boxes are made by the box shop. (Wife) Isn't this neat? This box. The other day, a 72 year old grand pa came in and ordered 25 of this box, so people will remember him after he dies. (To give out to his friends and family?) Yeah. He said he was going to give it to friends and classmates from his childhood. (It's interesting to blades!) Yes. (How about this kitchen knife?) That is a san-toku(three benefits) bouchou(kichen knife). (Has three benefits?) That's right. This can cut fish, vegetables, and meat, an all purpose kitchen knife. (Depending on the purpose of that particular kitchen knife, does the attaching of the steel differ?) No, the attaching of the vegetable knives and all purpose knives are the same. Fish knives and planes are the made the same way.  My
whole body is like made of muscle.These are all scars of a burn. I used to have a clear skin when I was young, but as I aged, it changed. (Do you work with bare hands?) Yeah, it's no good unless you work with bare hands. Because you need speed. Without speed, it would be slow. Wearing the finger covers. (Doesn't that melt?) Without finger-covers, it hurts because of hangnails. Not as bad in the summer though. (What's that spark coming out every time you hit it?) That is called KANAHADA in technical terms and when hit, thin scum floats. And when struck with water on it, it causes it to explode. Sucking the iron powder. (Do you ever hurt your body, since the job requires strength?) No, not really. When I was young, I once flipped over with a motorcycle and shattered the helmet, but I didn't brake a bone. I guess my bones are flexible. If I weren't, I would probably be injured somewhere. But, yeah, I'm losing strength in my fingers. Since I carry heavy things. There are times when my fingers don't move precisely. And my body is like all muscles. |
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