Ghost Structure Workshop Synopsis: Amelia Hughes

AMELIA HUGHES IS AN ARCHITECTURAL HISTORY STUDENT AT THE UNIVERSITY OF VIRGINIA. 

Earlier this Spring I was very fortunate to have the opportunity to spend two full days working with a crew at the Menokin site in Warsaw, Virginia to build a reconstructed slave dwelling on the site where one of the historic plantation’s slave cabins had once previously stood. The actual building of the structure was an effective blend of traditional and modern tools and techniques. At Menokin, the crew employed a combination of both modern and historic building technology to achieve the end result of the slave dwelling structure. I  found this juxtaposition between eighteenth and twenty first century technology to be very intriguing. Throughout the two days that I spent working with the crew, I was able to gain experience using both modern power tools and hand tools, some of which were themselves antiques forged by blacksmiths. I appreciated the way that the crew used modern time (and therefore money) saving tools while still using traditional methods for many aspects of the construction. In one instance in particular, this blending of modern and traditional tools especially stood out, and that was in the creation of the mortis and tenons used to construct the building.

The first step in the process was to create mortises in the cut lumber that the structure was going to be made out of. In order to do this, we used an electric powered mortise maker. This tool is essentially a chainsaw oriented vertically in a frame that can be adjusted and pushed down into the wood to create a rectangular hole that serves as the mortise for the timber frame constructed building. The tool, however, created a cavity with rounded corners and humps in the middle where the mortise machine could not reach due to it’s rounded blade. From this point, the most efficient way to shape the mortise was using the tried and true methods of the eighteenth century and prior – with a chisel.

A chisel and mallet was the most effective way to complete the mortises and shape them into the required form in order to properly fit together with the tenons to create a secure joint. Effective, that is, if you are skilled in using a chisel and mallet. I however was decidedly not effective in my chiseling efforts, and it took me a great deal of time and effort in order to adequately clean out even one mortise.  Chisels of varying sizes were actually one of the most, if not the most, used tools on site among both traditional and modern power tools. The chisel was also used to complete the tenons after they were cut out of the lumber with a circular saw. The modern power tools made for quick and easy work, but that was not precise enough to successfully complete the traditional construction techniques. In order to properly execute the mortise and tenon joints of traditional timber framing, old-fashioned hand tools were needed to shape the joints to the point where they would properly fit together.

This combination of modern and traditional methods really struck me. We can improve upon the building methods of the past using our current technology, but sometimes the best tool for the job is still the original tool, as was the case in creating mortise and tenon joints. The methods of the past sometimes can only be achieved using the tools of the past, despite our best efforts to cut down on the time and labor expended in the building process. This blend of historic and contemporary building was also apparent in little shortcuts that the crew took. One example of this is that when cutting big pieces of wood out of the sills for lap joints, the crew made a few strategic cuts, gave a couple of whacks with the hammer, and out popped three blocks of wood that used to occupy the space that was now made vacant for the lap joint. Removing the wood in that way allowed it to break along its own natural path, making it easier to chisel the precise measurements needed and ensuring that the wood didn’t break or split due to unnecessary excessive pressure from a power tool on an a relatively small piece of wood. I appreciated the crew’s mix of old and new techniques. It seems wise to keep the best of the traditional methods while using available current technology to make the process more efficient.

I was a little surprised to learn that the building crew which readily employed modern technology in their construction, still made pegs to hold the mortis and tenon joints together using traditional methods. I expected them to have some sort of peg making tool but was informed that this is not the case. That meant I was back on the saw horse, and I am pleased to report that my band knife skills are coming along quite nicely, as well as having made some very beautiful wood shavings a photo of which is now the background on my phone. We needed to make about eighty pegs to complete the construction, and we did all of them by hand using the traditional

(L) Correct peg (R) Incorrect peg

methods. Unfortunately, there was a bit of miscommunication and the majority of our pegs ended up being not quite wide enough, so we had to go back and shave off some additional wood with the band knife. The pegs needed to be long enough to go completely through one piece of framing and into the next, securely attaching them together.

And so we learned the hard way the importance of triple-checking your work, especially when using labor intensive hand tools, by having to go back and alter fifty pegs by hand on the saw horse.

As was the case in working with wood in class, it was important to keep the characteristics of the wood in mind when manipulating it in order to create the components necessary for a timber frame structure. When we began making tenons to fit into our perfectly chiseled mortises, we had to keep the properties of the wood in mind. After carefully measuring out our tenon from the lumber that would soon become a wall stud, we set about cutting the shape out of the wood. Perpendicular to the wood we used a hand saw, but cutting parallel to the wood, we used a chisel to remove the small block from the larger piece. This was because it is most effective to saw against the grain as opposed to with the grain, and when going with the grain, the most effective tool is a chisel. In the work of constructing a building, it is always necessary for the carpenter to keep the properties of the wood in mind and work with those properties, using them to the carpenter’s advantage when possible, as opposed to against it.

Throughout the days spent at Menokin working on the slave dwelling, we also learned some of the traditional hand tool technology that would have been used in creating a structure similar to what we were making. Craig Jacobs demonstrated, using antique hand forged tools, how a log would have been hewn into the type of usable lumber that formed the structure of a timber framed building. We learned about the process of scoring the log with an ax, “juggling” the resultant little mounds off of it, and then hewing that last bit to create a mostly flat surface. I especially liked the ax with an offset handle made for the last step of hewing. It is such a specialized tool but trying to hew that last bit with a regular ax was near impossible, and I have to think that the first few people to come up with offsetting the handle must have been amazed at how much easier that made the task, and awfully pleased with themselves for their innovation. It was really interesting to see how the timber would have been made, and I think that Craig was a bit surprised when we told him that we wanted to try to hew a log of our own. Attempting to hew a log into usable lumber was incredibly difficult. But much like splitting a tree trunk using only wedges and mallets, it was also immensely rewarding. It felt really good to swing an ax and knock off a clean chunk of log almost flush with the chalk line. I have to admit that these moments were fewer than the ones of frustration, but the process made me really appreciate all of the skill and man hours that went into constructing timber frame buildings.

All in all, I really enjoyed my experience working hands on with a modern take on traditional timber frame construction. Learning about how the pieces fit together in class is one thing, but actually seeing how it is built and watching it come together adds an additional depth of knowledge that can’t be gained any other way. I have such a greater understanding of early American building practices and how a timber framed structure is created. Understanding how tools are used to shape and manipulate the wood to fit together perfectly provides me so much context that cannot be grasped from simply reading about it. I am so glad to now have this deeper connection to and understanding of the process of creating timber frame structures and the skilled laborers who built them.

I got home from Menokin on a Tuesday night, and on the following Wednesday I went to our neighborhood weekly meal at our common house, part of which is an old log cabin that has been added onto multiple times. I went into the cabin and looked at the timber, like I have many times before, but this time I noticed marks on the summer beam that I hadn’t appreciated before.

They were the marks left behind from the hewing process, little V-shaped notches in the wood where the ax score marks had gone slightly past the chalk line, marks I had just made myself on a piece of timber at Menokin. And seeing those scars in the wood made me love that little cabin more than I ever had before.

 

 

Community Idea Station WCVE Shines A Light On The Menokin Ghost Structure

We’d like to thank Inigo Howlett, the Northern Neck correspondent for Community Idea Station WCVE for paying a visit to Menokin to learn more our Ghost Structure Workshop that took place in May.

His news report aired on May 29th in the Richmond and Northern Neck areas. If you heard the story, or even if you didn’t, do one or all of these things:

  • Listen to it now online.
  • Search “Ghost Structure” on the blog to find related stories and to see more photos.
  • Visit our website to learn more about the Menokin Glass House Project and the important, innovative work taking place here.
  • Come for a visit, take part in a program, or go for a paddle on Cat Point Creek.

If you like what you see, hear, experience, learn…make a donation!

Here are some pictures of the completed, glowing Ghost Structure on the Menokin landscape.

Ghost Structure Workshop Synopsis: Julia Judd

Highlight of Day One

On the first day over a cool cast of clouds the project for the Ghost Structure of Menokin began to create the first replica of a slave dwelling that once was built on this land. The group was split up between two groups to start cutting the wood. Both groups would contribute in building the base of the structure. In order for the base of the structure to connect the joists must be cut into the wood. The joists are made up of horizontal timber and in our case, oak is being used as the base because this type of wood particularly is harder and will hold up the best support. In creating the joists each end of the timber must measure 4” x 4.5” in the shape of an ‘L’. A japan saw is used to cut off the unwanted piece in 4 sections. Next, a chisel and mallet are used to break off the sections to create the final joist.  Pictures below show the process of creating the joist.


Highlight of Day Two

Once a 15’ x 25’ base is placed we began preparing the next steps in creating the floor of the Ghost Structure. The floorboards would be made of yellow pine and in order to align each row of the floorboards a hammer and chisel would be used to avoid any gaps in the floor. However, in the 18th century they would also use an auger that would create a small hole into the wood and another tool would be placed into the hole to wedge the pieces of wood together. An auger is a tool with a large helical bit for creating holes into wood. We know there is evidence in using an auger to wedge the floorboards together because of the circle marks left over by this tool. In our case, only a hammer and chisel were used to connect each floorboard together. Nails were hammered into the yellow pine to connect the floorboards to the base of the structure. Once a floor was established the frame of the Ghost Structure will become the next goal. Picture below shows finished floor.


Highlight of Day Three

On the first day the other group was creating joints in the base for base to properly support the frame. The joints are known as mortise and tenon and are adjoining pieces that connect at a 90-degree angle. On day 1, the mortise was first cut into the base to eventually fit the tenon to connect the frame to the base. Creating the main, vertical frame is what was being accomplished on day 3. This becomes the most structural support of the Ghost Structure. How would the mortises be created back in the 18th century? An auger would have also been used to create a hole for the tenon to be connected to. However, the auger would not penetrate entirely through the timber but a little over halfway through so when the tenon is created is has a stopping point. Picture below shows the joists creating the base and the main frame connecting to the base of the structure. Third picture shows how the tenon is being cut by using a japan saw that will fit into the mortise.


Highlight of Day Four

Hand-carved pegs were needed to be made to act as the studs of the structure for better stabilization and support. By taking a long piece of yellow pine that measures roughly 1” x 1” and carving out the shape of the peg by using a tool known as a draw blade. The tool does exactly what it is named for. When using a draw blade, you hold onto the handles on each side of the blade and pull the tool towards yourself to smoothly shave off pieces of wood. In our case, sat on a sawhorse that allowed us to clamp the piece of wood tightly so that the draw blade could easily be used. About 90 pegs were carved over the course of the week to be hammered into the Ghost Structure.


Highlight of Day 5

After the pegs were finished, they needed to be hammered all around the base of the structure. An auger would have been used to initially created the hole for the peg to fit into. For the purpose of finishing the structure within the 5-day mark, a power drill was used. The pegs had to fit in tightly and once hammered in the piece sticking out of the base had to be sawed off using a japan saw to fit smoothly along the oak base. Once the pegs were placed the cripples had to be attached to the vertical frame. Cripples are a type of wall bracing that rests on top of the foundation of a structure. They support the overall weight of a building and must be braced so the frame does not collapse. Both ends of the timber cripple are cut at a 45-degree angle and hammered into the frame.  Pictures below show the drilling of the hole for the peg and then using a mallet to hammer in the peg to the base. The last photo shows how the  cripples were hammered in with nails to the frame of the structure.


SEE MORE POSTS ABOUT THE GHOST STRUCTURE WORKSHOP:

Learning and Lounging on Cat Point Creek

Dr. Duane Sanders, River Program Coordinator, Biology Instructor

Students from St. Margaret’s School Outdoor Adventure program spent three afternoons in May kayaking on Cat Point Creek at the Menokin Plantation. Students learned about wildlife supported by this ecosystem and how the system can change over time. They also relaxed and had some fun!

Menokin Ghost Structure: Playing Catch Up

IN CASE YOU MISSED THEM: DAY 1 AND DAY 2

 

How sad is it that the crew can build an entire structure faster than I can blog about it and post pictures? Very sad.

DAY 3 – Wednesday

The day was made more interesting by the arrival of two groups of horticulture and carpentry students from the Northern Neck Technical Center. Most of the students had never been to Menokin before. I was so pleased to hear many of them say that they “sure didn’t expect it to be like this!”

In case you didn’t know, May is Preservation Month. The “This Place Matters” campaign was started by the National Trust for Historic Preservation many years ago to bring attention to the importance of historic buildings to local communities as well as visitors and enthusiasts.

 

DAY 4 – Thursday

Raise the Roof takes on a whole new meaning when you see it happening. All the chiseling, measuring, staging and peg making were put to the test with the assembly of the structural timbers and the crown of roof rafters. The beautiful bones of the building are a perfect addition to this vast, cultural landscape.

Get Floored By The Progress

The Menokin Ghost Structure: Memoria and Kairos – Day Two

Day One ended with peg manufacturing in full swing (need 80 total), the grade beams of the structure assembled and the chiseling of the mortise and tenon joints well underway.

By lunchtime on Day Two, the floorboards were cut and laid. Preparations for the framing of the walls began in anticipation of the vertical beam raising to take place on Day Three. And let’s not forget the fashion show of the Fab Four students voguing their Menokin hats.

Take a virtual stroll through the pictures and imagine the scent of fresh-cut pine perfuming the air; hear the scrape of draw blades shaping pegs; feel the delicious spring combination of warm sun and cool breeze on your skin and get floored by the progress being made on our newest interpretive tool at Menokin.

The Menokin Ghost Structure: Memoria and Kairos

MAKE SOMETHING WITH YOUR HANDS

This structure will be 15ft x 25ft. The enclosed wall surfaces will be transparent and developed in the future for educational interpretation. Participants are spending the week learning wood working and joinery techniques that were used in the 18th century.

Based on information derived from archaeological excavations, we will be recreating the framework of a dwelling that would have been lived in by Menokin’s field slaves.

DAY ONE: The Work Begins

MAKE SOMETHING WITH YOUR MIND

THE MENOKIN GHOST STRUCTURE serves as a physical metaphor to foster discourse and assist people in forming and participating in conversations about slavery as it relates to the Menokin site, the history of America and current events.

MEMORIA is a Latin term, and can be translated as “memory.” Memoria was the discipline of recalling the arguments of a discourse in classical rhetoric. Creating outline structures of the major arguments of a discourse would also aid memory.

KAIROS dictates that what is said must be said at the right time. In addition to timeliness, kairos considers appropriateness. The term also implies being knowledgeable of and involved in the environment where the situation is taking place in order to benefit fully from seizing the opportune moment.

The size of the building is known from the archaeological evidence. However, because there are no photographs of it, we are recreating only the timber framing of the structure, which will be clad in a transparent sheath. We are calling this building the Ghost Structure: Memoria and Kairos.

 

 

 

 

 

 

 

 

The design, drawings and renderings of
the Ghost Structure were created by architect Reid Freeman, who also serves on the Menokin Board of Trustees.

 

 

 

True to our unique vision, we are not creating a reproduction of a slave dwelling, but instead a constructed form that will generate dialog about our past, with the flexibility to garner new knowledge, awareness and understanding. Once completed, this structure will be used as an educational classroom, and will serve as the centerpiece in telling the African American story – both past and present – in Richmond County, Virginia and beyond.

 

 

 

 

 

 

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