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Bat
Making Process
Step 1
Trees cut down.
Cricket bat willow
is a cultivated timber which grows in large plantations in wetland
areas throughout Essex, Suffolk and Norfolk. Each tree is
individually planted by hand and during its natural life-span, the
willow will be tended by the grower to ensure that the tree will be
suitable for bat making. For each willow that is
felled, two new trees are planted. In this way the industry,
countryside and the actual species are protected. Cricket bat making
is a craft based on conservation.
Step 2
Willow clefts ready for grading and
machining.
All our timber is
sourced either from willow specialists. Choosing mature trees
(between 15-30 yrs old), cutting them into rounds, then splitting
out the clefts is an occasional luxury, as the majority of our time
is dedicated to the actual making processes. The bulk of our willow
therefore comes from willow specialists but each cleft is still
selected by Ajit Menon by hand. The cleft has already been split
from the round (section of the trunk), rough sawn, the ends waxed
and then air or kiln dried to reduce the moisture content. The
waxing is essential as it prevents quick moisture loss from the end
grain which could cause cracks or drying 'cones'. Any clefts
suffering from these cones are filtered out of production, or, if
finished, sold only as substandards directly from the
workshop.
Step 3
Machining a cleft to
width.
Once in the workshop, the cleft undergoes various machining
processes to be cut into the basic blade shape. Even at the
machining stage, the craftsman's expertise is essential as the blade
must be continually evaluated in order to maximise the natural
potential of the willow; for example establishing the best end for
the handle and leaving the most suitable wood for the driving area.
There are no shortcuts as every willow cleft is unique and must be
assessed throughout the production processes if quality, strength
and honesty of grading are to be guaranteed. The skills involved in
machining, and its importance to the integrity of bat production is
why we have invested so heavily in our workshops. Self-sufficiency
as a brand is paramount. Many companies sub-contract machining and
pressing, or even buy in nearly-made bats (we ourselves provide a
restricted machining service to a number of these brands).
Step 4
Blades ready for
pressing.
Once the blade has been
correctly graded and machined, the next stage is the pressing. The
willow fibres have to be compressed in order to strengthen the
timber sufficiently to withstand the impact of a cricket ball. But
as pressing is a delicate balance between hardening the willow for
strength and leaving the blade soft enough to play well
(over-pressing can deaden the blade), DKG presses each blade
individually. Generally, we press the blade up to 4 times at up to
2,000lb per square inch. Again, inherent understanding of the wood
is essential to determine the right amount of pressure. The press
itself, which was custom built, is adapted for different models and
constantly developed to maximise performance and durability.
Step 5
Handle being spliced into a blade.
The handle, a laminated
construction of cane and rubber strips (treble sprung), is fitted
through the precise splicing of the handle into the blade. The
craftsman will set the handle slightly forward of the blade ensuring
a perfect pick up once the bat is made. The handle is secured using
a water resistant wood glue and left overnight to dry.
Step 6
Pulling off a bat.
The blade is shaped by 'pulling
off' the willow with the draw knife. The bat makers will leave
maximum wood in the driving area whilst working the blade to
establish the balance that is associated with the finest handmade
bats. The coarse cuts of the draw knife are smoothed using wooden
planes and the shoulders and handle are seamlessly blended with the
spoke-shave. The toe is very carefully shaped to a distinctive angle
for strength and protection.
As with all the other stages of production, the hand shaping is absolutely unique to each bat. During the shaping, the bat will be removed from the vice and tested for balance and form by the bat maker, using his knowledge of the game as a point of reference for balance and pick-up.
Step 7
Drum Sanding.
Once shaped, the bat
will be both course and fine sanded. Like the shaping, the sanding
is dependant upon the eye and skill of the craftsman. The
characteristic finish of a DKG bat can be attributed to very
fastidious sanding, which has always been a point of
pride.
Step 8
Binding a handle.
The handle is bound using the finest quality twine. The bat is mounted in a lathe which is controlled using a foot treadle; the handle is brushed with glue and whipped with the twine which provides strength at the top of the splice and throughout the length of the handle. The blade is then finely burnished using a compound wax which polishes and flattens the wood leaving a satin finish.
Note: traditionally bats were 'boned' instead of polished - the use of a bone or piece of cane to compress the fibres giving both the final finish and a final pressing. With Matrrixx and any good bat production, if the pressing and sanding are correct, then the finish is obtained though burnishing, so 'boning' is never necessary. The key to our finish is not a bone or a clever polish, but the quality of the sanding.
Once bound, English grips are fitted to the handle and labels are applied to the face, back and sides of the bat. All our bats then undergo a final quality inspection, before being packaged and distributed to shops around the country. With each bat is carried the hope that the time and effort we expend will be rewarded by the owner's care and attention, and great success at the wicket.
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