1930's Replication
New frame replicated from the original seen in the background.
Double box-tied springing in process.
Front row integrated with the deck springs
Double-return knots. Springs sewn to webbing in four places.
Hand-filled edge rolls stitched in at the frame's profile. Support rail has been rounded over with hair and burlap.
(this photo from original restored frame)
Hair being formed into shape approximately three inches deep, reducing according to arm's profile.
Loops of string secure the hair in place.
Finished layer of horse hair.
Hair is topped with a layer of cotton batting.
Muslin pulls the padding materials into shape.
The final profile.
Back-springs sewn and tied in place.
Waxed sisal cord was used in the absence of like-grade flax or hemp.
Completed back-springing.
A regulator is used to lace back springs into the burlap casing.
Top profile is shaped with hand-filled rolls.
Stuffing "squared up" with the weave in the burlap is essential.
Original and replica ready for further stuffing.
Center section filled first.
Three and a half inch fill.
Establishing depth of seat.
Back padding measured forward to the deck's edge roll.
Depth of hair adjusts with bridle-tie tension and rigorous picking with the regulator.
Depth tapers off as the crown is established.
1 1/2" hair over the top.
Hair is covered with cotton batting.
Muslin pulling down padding materials.
A draw-string in the muslin pulls in the profile evenly.
End cushions being filled.
The regulator is the most important tool in managing horse hair.
Two shipments of hair show the varying colors and a defining line.
Muslin over cotton and hair, pulled down to exact dimension.
This picture says it all...
Leather and deck cloth sewn to hand-shaped edge roll.
Cotton over edge roll.
Cotton breaks with wire stitching.
Leather is pulled over and sewn to the edge-wire framing.
Surgical steel needles are essential.
Even application of the leather is adjusted in cinching the knots.
Completed deck cover sewn to edge wire.
One inch layer of hair being placed over cushion deck.
Even placement of hair along deck gutter.
Cotton over one inch horse hair deck.
Denim strained over deck padding.
Additional hair to fill outer edges of spring deck.
Completed gutter.
Top band cording sewn just above the edge-wire.
Hair in place under top band.
Cotton over hair in the upper band.
Second band being padded with cotton.
Both bands completed.
A drawstring shapes the arm profile.
Drawstrings pull leather tightly and evenly.
Pleats are stapled into place.
A one inch cotton-filled cord adds unique detailing.
Drawstrings used to round off the back pillows.
1/2" stitches are ideal.
New arm facings were cut and panel nails flush-fit.
Sheet metal notchers are handy for cutting even curves in cording.
Faced and ready for closing up. Feels like a boxing glove...
Notchers help when sewing cushion covers.
Lochner stuffing machine.
Marshal unit springs inserted in muslin sleeve.
Layers of cotton build from the bottom up.
Marshal unit is boxed in with cotton around the edges.
Reversed formula tops off the springs.
Layers of cotton tucked in evenly.
Pans are secured and compressed.
Cushion cover is aligned with the stuffing pans.
The foot pedal extrudes the Marshal unit into the cover.
Fitting the cover to the stuffing pans helps insure an even fill.
A firm grip from the sides insures a tighter fitting cushion.
Circa 1930-2007
"Jaybee" France and Me... He's the extra hands behind the scenes.