May 22 – 28Bronze Casting Festival at the Bronzezeithof in Uelsen, Germany. It’s a festival for bronze casters to meet, exchange knowledge, work together on castings and experiments, discuss methods, and have a good time together. For more information, check out their website. I plan to be using new (to me) medieval mould recipes and casting more replica tools. The site is a Bronze Age village, and I will have an exciting time living the Bronze Age life for a couple weeks. No internet! I’ll have a lot of time to write and plan to keep a diary of the event that I’ll upload when I return to the 21st Century.
June 6-10 The 14th annual Nordic Bronze Age Symposium will be held in Oslo, Norway. I’ve been asked to participate in the conference and speak about interpreting mistakes made in metalworking. These mistakes often tell us much more about the craft of metalworking than the perfect pieces that are usually held up as examples.
July 1- 8 I’ll be returning to Sedgeford for the SHARP metalworking workshop. We’ll be teaching archaeologists and other volunteers there how to build furnaces, cast metal, and maybe even smelt some iron.
I’ve launched a Patreon Page to help fund the various projects and workshops I’m involved in. Interested in supporting experimental archaeology and the sharing of information? Your support through Patreon will help make things happen. As a supporter you’ll get rewards including copies of articles I’ve written and reports from the field. Check out the page on the button above for more information.
Recently this story about the Skrydstrup Woman made the news. Strontium analyses showed that she was not born in the same region where she was buried. Rather than coming from what is now Denmark, she started out life farther south in Germany or France. Like the Egtved Girl (better known for her infamous string skirt) she was a member of the elite society, buried in an oak coffin, wearing gold jewellery, and embroidered robes. All of those items buried with her would have meant the sacrifice of objects that would have taken many days or even weeks of labour to manufacture. Her hair was put up in an elaborate style, that would have required assistance. Her bones indicated she lived a healthy life and died from unknown causes when she was in her late teens. She arrived at Skrydstrup when she was about 13 or 14 years old.
It’s possible that she arrived in Skrydstrup as a bride, marrying into a local noble family to cement a political alliance, or perhaps her well-born family relocated to Skrydstrup. We can make up any number of stories about her personal history, and no doubt many will come out as further analyses is done and technology improves. What remains is that she travelled a long distance in her life, and possibly not just going directly from where she was born to Skrydstrup. She could have travelled to several places in her short life.
I can relate to the Skrydstrup woman. By the time I was her age I had travelled from where I was born in southern California to San Francisco, from there to the Upper Peninsula of Michigan to Milwaukee and Chicago. As an adult I’ve lived in both North America and Europe. It used to be assumed that people lived their lives in a single community, but then as now, we see that people were mobile. This mobility not only brought a single woman into a community, but also her way of life. She would have spoken at least one other language, a useful skill if her family or that of her husband were merchants. She might have brought other valued resources to her community, such as a new type of needle working, weaving, or other skilled crafts. The objects from her home would have been seen as exotic, foreign, or rare.
The history of archaeology has been full of explanations for the movement of people. At times they were described as political conquests or invasions, the Beaker Folk, Anglo Saxons, Vikings… each generation giving a different interpretation of the data we have. Were they marauding warriors replacing the local population, groups fleeing strife in their homeland, or peaceful settlers arriving with families? Or some of each? The evidence we have in prehistory comes from changes in material culture: a new style of pottery, the introduction of a new technology, or changes in the way the deceased are dealt with. In some cases these cultural changes can be dated and tracked, allowing us to look at the progression of something, such as a craft techniques, from its origins and disbursement. However in tracking all the data on all these objects the humans sometimes get left behind. The bowls, beakers, and axes didn’t move themselves. People were travelling, carrying them, moving from one place to another. It makes sense, humans have been on the move since the beginning. From small bands in Africa, humans have spread out over the entire planet. We continue to move and migrate as groups and individuals to this day, bringing skills, languages, and ideas with us. Creativity, adaptability, and mobility are human strengths.
The Skrydstrup woman puts a personal face on migration. Both she and the Egtved Girl were immigrants, although for years they have been an icon of Danish prehistory. Now their story has expanded and rather than a symbol of a single national identity, they represent the multicultural world of human prehistory.
Archaeological textiles is a difficult specialty since most of the material deteriorates rapidly. It is rare when prehistoric textiles are recovered. However, what textile archaeologists do have for study are the tools used in making textiles: spindle whorls, loom weights, combs, and other tools. When I go to museums, I often look at objects outside of my own area of interest and in the following pages, I’ll be providing some support for my friends who work in textiles.
Please note that many of these photos are taken from outside glass cases and can’t provide measurements and weights. However, I will do my best to provide as much information about the context as possible.
Textile tools in the Bologna Museum of Archaeology
I took some photos of textile tools while on a recent trip to the Museum of Archaeology in Bologna. The cases were nicely organised by context. That is, rather than group all the spindle whorls together and all the beads together somewhere else, the objects were grouped according to where they were found. For example, if they were found in a burial, all the grave goods were displayed together, so all the beads, spindle whorls, and other objects were on the same shelf with a card explaining the context and how the objects relate to each other. I have undone this a bit because the focus here is on textile tools. However, I will provide as much information as possible so that you will be able to do further research if you wish.
Spindle Whorls and Weaving Weights
Spindle whorls and Spindles (Conocchie)
Representations of the Textile Industry
This object, a Tintinnabulo, described as a ritual pendent was part of a lavish burial in Tomb 5 of dell’Arsenale Militare (700-675 BC, Villanovan III) and depicts the steps in wool processing. Drawings show the engravings that are on the front and reverse of the tintinnabulo. More about the tintinnabulo and the burial can be found here.
Textile tools in the The Civic Museum of Archaeology and Ethnology, Modena
Textile tools in the The National Archaeological Museum in Naples
I have a couple of the fibulae I cast up for sale on Etsy. If you’re in the US, this will be your last chance for reduced postage for a while since I will be leaving for Italy on the 14th. Think of it as a one week sale where you’ll not only save money, but your purchases will also arrive much sooner.
This autumn I was visiting my sister who lives just outside Albuquerque, New Mexico. She has a bit of land, so I asked her if I could build a furnace and do some casting there. I’ve built plenty of pit furnaces, so this time I wanted to build one that was above ground and a bit more visible. It would also mean that no one would trip and fall if they forgot where I put the thing.
First off was to get the basic materials: Clay, Sand, and Horse Manure.
I thought that the clay would be the biggest hurdle. However my sister’s neighbour happened to be a sculptor who works in both iron and ceramics. She went to her regular clay supplier and got a couple feed sacks full of dried clay for free! Potters who work at wheels, or work with kids end up with a lot of clay that is scraped off of workbenches and wheels that is hard to re-use. It’s often mixed consistency, lumpy or part dried. If they want to use the clay again, it has to be reconditioned. So, they take their sacks of scrap back to the place where they buy the clay and pay to have it put through the mill. Since it’s not really usable, some potters are willing to just give it away. So thanks to Liz Fritzsche, who does amazing and beautiful work in porcelain, I was able to get started.
I threw some of the dried clay into a five gallon bucket and poured in enough water to cover the clay and let it sit. It was squishy and workable in a few hours. Next up was horse manure. A friend of a friend has horses, and they were grateful to have someone who would haul away a couple of barn buckets full. The final bit was the sand. My sister did have some beach sand that she’d bought for the garden, but I was more fascinated by the soil there. Her land is in the old Rio Grande River Valley, and the soil is a mixture of silty sand and a little clay that had been pounded to a powder. The soil was almost the consistency of dust. It mixed in perfectly and later I found the mixture was highly resistant to cracking.
The ingredients were mixed with some water, stomped, and adjusted. New Mexico is a lot drier than England, so I ended up adding more water as I worked. It was also nice knowing that it was unlikely for any rain to fall while I was working.
The silt/clay/dung mixture made a durable clay, and after I flew back to Minneapolis, I was please that the crucibles and moulds I packed in my check-in luggage survived airport handling.
The furnace walls are about 8 cm wide (about the width of my palm) and the inside diameter is about 25 cm in diameter. I let it dry for a couple days and then moved it over to an unused area behind a greenhouse where I would have more room to work. I set a small fire with cottonwood branches, fed it for a couple hours, and then let it die out overnight.
We all like to put some decoration on our furnaces. My students have done everything from dragons and demons to cats. I had been thinking about doing some imitation petroglyphs, but as I was working it just seemed natural to do a portrait of Mavis, my sister’s exuberant German Shepherd.
Finally I adjusted the mix to have a bit more of the silty sand and horse dung to make the teapot stand and crucibles. For more information about teapot stands and how they work in furnaces, check out my article on the Umha Aois website here.
Later I added more water to make the slip for dipping waxes in for the first stages of mould making. The silt made a wonderfully fine mould that picked up all the details.
I had some cracking on the upper part of the furnace, and noted that the part that cracked was where I used the commercial sand. The silty New Mexico soil held up much better. If it weren’t so heavy (and probably not allowed) I would have hauled bags of it on the plane to use for more projects.
Both Mavises performed very well (Mavis the Dog is into barrel racing and advanced obedience classes). I’ll be interested to see how it holds up over the winter. Winters in New Mexico tend to be mild, so I’m hoping that the Mavis furnace will be available for friends in Albuquerque to use for some time to come.
Sometimes you just need a new pair of shoes. I’d been wanting to make some of the replica shoes I’d seen online. there are a few good sites where you can find patterns and step by step tutorials.
Kelticos has a number of different patterns that you can download.
I followed the instructions on this site. It goes step by step and practically no-fail. I however am a bit more cautious and rather start with the leather I made a pattern out of brown paper.
Once I was confident that I had a good fit with the paper pattern, I bought the leather that I needed. One thing that few sites describe is the type and weight of leather needed. I bought some cow leather that was supple, but not stretchy from Cox Leather in Abuquerque. The place is an amazing resource for hides, rawhide, leather, skins, and really anything leather related. They also ship!
Leather thickness in the US is measured by the ounce, and in mm in Europe. The leather I bought was about 8 oz / 3.2 mm / 1/8 inch thick.
Once I traced the pattern on the leather, I cut the shoes out using good sharp scissors and punched the holes for lacing with an awl. It’s important to use an awl or punch rather than cutting the hole with a scissors since a round hole pushed through the leather is less likely to tear than a hole that is cut.
I stitched up the backs with sinew. I followed the directions and stitched the sides of the heel to the heel tab straight up. It ended up a little loose. When I get the time I’ll restitch them so they come in a little tighter on the top. Another modification will be to put more of a sole on them. Some options are to cut an insole out of rawhide and sew it between the inside of the sole with another, softer leather insole on top. I might line it with some sheep skin, too.
I’ve been honoured to cast alongside Billy on a number of occasions while we were both at Umha Aois events. His recent article for the Pallasboy Project: Art, Craft, Archaeology, and Alchemy talks about his experience in both experimental archaeology and craftsmanship.
I have a fascination with bellows. We know they had to have existed in the Bronze Age, but unfortunately they are also constructed of ephemeral materials, so none have survived into modern times. The only physical evidence we have consists of fragments of tuyeres. An Egyptian painting from the Tomb of Rekhmire, from 1450 BC shows a man using pot bellows that are operated by hands and feet. There are also Chinese documents depicting the use of box bellows. But bellows, after blowpipes, are likely to be one of the earliest forms of delivering air to the furnace.
Until a set of bellows is uncovered preserved in a bog somewhere a lot is left to the imagination. How big or small could they be? How can the valves be altered to be more efficient? How heavy should the leather be? Should sturdiness trump suppleness? How are all the parts held together and made airtight? Bellows are one of the most essential pieces of equipment that we have for casting bronze and yet very little information is available about their use and construction from the community of experimental archaeologists and reenactment groups.
Over the years I’ve seen many different shapes and sizes of bellows and always thought that a forum where bellows design and use could be discussed would be invaluable for people to share ideas and experiences.
I would like to invite others to share photos of the bellows they’ve made on this site. This could be a welcome forum for discussing the pros and cons of different designs, what worked, what didn’t. Of course any news of archaeological bellows or tuyeres discovered would add to the fun.
To start, Martijn van Es sent me some photos of a set of bag bellows he made and photos of a new set he recently completed using the tutorial on this website. Martijn casts bronze at the Bronzezeithof Uelsen and Het Bronsvuur – The Bronze fire and is active on the web and Facebook discussing Bronze Age casting techniques and projects that he’s involved with.
Other bellows designs
This has to be my favourite bellows idea. Simply made from two cement bags.
I welcome others to send in photos of their bellows, and not just bag bellows. Any bellows that could be considered to fit in with what we know or can surmise from archaeology would be interesting for this forum.
If you are interested in making bellows for yourself but don’t know where to start, check out the tutorials on my site for making bag bellows and for making pump bellows.
Bone needles are one of those things that are a useful part of any experimental kit. They are easy to make, durable, and work better for sewing leather and hide than many steel needles. If they do break, then it’s easy enough to cut off a new bit, drill a hole and sand it down to a glossy, slender tool. The best bones to use are the long bones, a humerus or femur.
Recently a particular bone needle made the news. A 7 cm needle made from a bird bone was found during an excavation in the Altai Mountains in Russia. You can read the full article here. Finding a needle in an excavation is difficult enough, but finding one intact after 50,000 years is extraordinary.
However, in this context this needle is much more than just a needle. First we must think about the technology and tools that went into making the needle. It had to be cut and shaped with stone tools, and then there’s drilling out the eye. Once we start thinking about making something as simple as a needle, suddenly an entire toolkit appears, and then there’s the other direction: how was the needle used and what was it used for? Materials such as leather, string, and textile rarely survive in the archaeological record. Could the Denisovans have been sewing hides into clothes? Making shoes? Sewing smaller skins into something larger such as blankets or tents? A world of missing material culture suddenly becomes imaginable.
Small things like this needle should put to rest the image of the “caveman” with ragged animal skins. These people were likely to have been sewing clothing!
Tuyeres are the tubes that bring the air from the bellows to the furnace. They can be made of wood, ceramic, PVC pipes, copper pipes, really whatever you can come up with that will do the job. They are usually connected to the bellows, but in some cases they can just be set close enough that the air is delivered through them to the furnace. If you have a set of two bellows, the tuyeres are in a “Y” shape, with two ends connected to the bellows that connect to a single end going to the furnace.
Archaeologically there aren’t many remains of tuyeres. There are some fragments of tubular ceramic objects that had evidence of burning on the end. However, the best example is a wooden one recovered from a Danish bog. This was the same sort of “Y” shaped one described below.
Quick and easy: Tuyere #1
One of the problems of working with kids is that they are so fascinated with flames that they sometimes don’t realise that the bellows aren’t the part that supposed to be burning. So I’ve been working on making a couple of new sets of tuyeres.
I’m under a deadline for one set, so this one is a quick and easy version. I pulled a good sized forked branch from the woodpile and cut the ends so they were fairly even. Then I got a 22 mm spade bit (aka: a flat bit). Then I just clamped it into a vise and drilled into the flat ends of the wood until the holes met near the centre. I removed the bark, rounded off and sanded the ends. I don’t want any bark that will work loose over time, or any sharp edges that will abrade the leather.
These will be connected by leather tubes to the bellows and held in place by strips of rawhide. Skip down to the section on putting them all together for the details on that.
Note: Save that sawdust you’re generating with all that drilling. It will come in handy for making moulds!
Larger and more labour intensive: Tuyere #2
The next one is another wooden tuyere for a new set of bellows I’m making. It’s larger, so the spade bit isn’t an option. Instead I cut the wood in half lengthwise and then carved out the inside with a gouge. It’s all handwork, so it takes longer, but one advantage is that the diameter of the air holes isn’t limited to the size and length of the drill bit.
The first step was to trim the branches and strip off all the bark and then saw it in half. Once it was cut, I marked off where I would carve out the centre and went at it with chisels and gouges. I made the interior as smooth and as even as possible. However, I don’t smooth the surfaces that will be glued together. They already fit well and the rougher texture will help the glue bond.
Ceramic and other Tuyeres
If your tuyere might be placed close to the furnace (as mine accidentally was), it would be a good idea to make a ceramic extension. This is just a tube made of the same ceramic you used for making the furnace or moulds. It can be fit to the end of your wooden tuyere with leather and rawhide, as described below, and the end can go straight into the furnace. The only problem I find with ceramic tuyeres is the possibility of them breaking when being transported or if someone steps on them.
At the Terramare Village in Montale, the tuyeres they use there have a 90 degree bend. The tuyere sits on the edge of a small, shallow furnace and blows air straight down onto the charcoal. It’s an Early Bronze Age design and does get hot enough to melt bronze and copper. If you don’t have much space for a furnace this would be an ideal solution. It’s also worth experimenting with different types of furnaces and set-ups to get an idea of how many solutions there are to the basic question of how to melt and cast metal.
I’ve also made tuyeres using the stems of Japanese knotweed. The stems are hollow, similar to bamboo, but much softer. The plants can get over an inch in diameter and several feet tall. The stems can be easily cut with a knife, small garden shears, or secateurs, and then the membranes between sections can be broken using a straight stick. Note:Japanese knotweed is a controlled invasive species in Britain. Any fragment of stem, leaf, or root will take root and start a new plant. They are almost impossible to get rid of once started. When I find a large stand of knotweed, I strip off any leaves and excess stem and leave them there. If I need to trim off any more once I’m home, I put it in a plastic bag and then put it in the bin.
As I said earlier, tuyeres can be made of anything that will get the job done. If you don’t need to have that “authentic” Bronze Age look, you can quickly whip something together with PVC plumbing or copper piping. It wouldn’t be glamorous, but as long as any flammable or melt-able parts are kept away from the heat of the furnace, it should get the job done.
At the EAA in Glasgow, I saw a poster showing the reconstruction of a beautiful horse-headed ceramic tuyere by Katarina Botwid of Lund University. You can see the tuyere in action here.
Putting them all together
The tuyere still needs to be connected to the bellows. I usually make tubes of leather that fit the tubes coming out of the bellows and the ends of the tuyere.This allows for some flexibility and gives you a bit more distance from the furnace.
Then I tie them in place with wet rawhide. Once the rawhide is dry, they are about as secure as you can get. If the leather is soft, the tubes have a tendency to twist or collapse, so a nice solution is to get some green willow twigs and roll them into a spring. Fit them into the tubes before doing the final attachment and they’ll keep the leather tubes open and prevent them from twisting.
By the way, if you have a hard time finding rawhide lacing, buy a rawhide dog chew. Soak it in a bucket of water overnight and then cut it into long strips while it’s still damp. If you don’t need all of it right away, let it dry out. Then when you need it again just soak it for a few hours and it will be nice and flexible again.