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Here is another phase of the bathtub construction.
The short and long sides are being laminated.
Next, we will prepare the bottom plank and proceed to assemble it together.
Otanoshimi ni mattete kudasai ne!

We started the construction of a nice sloped edge tub.
In this case we will document the construction process.
Watch out for updates!

In these pictures it is easy to understand how the side walls of a hinoki tub are laminated.
First the material is assorted so that knots or other imperfections get discarded and of course, so that the total width of the planks is equal on the four sides of the tub. This is also a way to optimize the use of the material and avoid loss.
The wood is hand sawn by overlapping 2 planks so that with one single cut two perfecly matching planks are cut.

The pictures show the phase when the planks are drilled and connected with woodes plugs (dabo). The planks are joined with a waterproof bond and kept in the press overnight.
The corner of the tubs are realized with a more complex joint which is sealed by the insertion of hinoki wood bark which acts as a kind of natural gasket. Moreover, this bark has excellent fungicidal property and prevents mold stains in the most vulnerable point (the corners).

What am I doing here!?

Actually, today we showed our material and products to a perspective customer from Germany who is visiting Japan.

It is always a pleasure to have a tea together and exchange thoughts with fellow westerners who share with us passion for japan and fine hand crafts.

We looked at the plans and after some talking, we felt it might be easier just to try one tub, as you would do with a pair of boots. We had an “outlet” tub and the client could enter and get a more direct idea of the size and of the feeling of the tub.
Even a smaller tub seems spacious and comfortable when you try it. No big surprise, the sizes we were recommending actually did fit perfect, anyway after trying the tub the client could feel reassured and move forward without worry.
If you visit Japan, drop by for a tub fitting (if you let us the time we can pick you up at JR Maihama station).

Well, we wanted to show you how it works so I found the good excuse to enter the tub myself…

Here is how we are building the 100% natural tub in the traditional way.
The shape most suitable is the “TARU” which is assembled like a barrell with vertical planks of hinoki. The water pressure distributes uniformly on the perimeter and is collected by the stainless steel bands hammered from the bottom up.

The hinoki planks are cut with variable angles so to match eachother seamlessly. Between these we used a natural bond made of rice starch called “SOKOI”. This is 100% natural and does not contain anything but rice and water!

Of course all our tubs are natural: we only use wood and do not treat it with any chemical or coating agent. How can you make a tub which is more natural than a wood tub?
Actually we do use some bond inside the joints of our tubs. We prefer epoxy bond instead of urea based products because it is long lasting and safe for the health.

Anyway this time we received an interesting challenge.
We were required to build a 100% natural tub (actually 2 tubs), without the use of any synthetic material. We had to resort to the knowledge and wisdom of our carpenter`s father who dedicated great passion and almost 3 weeks of work for this project. It was really a great chance for passing down the ancient tecnique (and art) to the younger generations. It was more than 50 years since he last used the this construction method!
Read some more details in the next entry.

Let me report the wise comment of our client (and friend):
“I am confirmed in the belief that Japanese were thousands of years ahead of us westerners: in the age when we were using perfumes to hide our odors and (in the rare occasions we were washing), we were using underwears and busts to hide our body, japanese were…

…bathing.

Naked. Alone or in good company. Clean in the mind and in the body.”
Also in this case, I cannot but agree…!