DURABLE PRODUCT-CRICKET BAT

Step 1 - Cricket Bat Willow

Trees are cut down

Cricket bat willow is a cultivated timber which grows in large

plantations in wetland areas . 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 protecting the environment and ecosystem.

Step 2 - Timber Selection

Willow ready for grading and machining.

All timber is sourced either from local trees or from willow specialists.
Choosing mature trees (between 15-35 yrs old), cutting them into
rounds, then splitting out the clefts is an occasional luxury, as the
majority of time is dedicated to the actual making processes.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.
Step 3 - Machining the Bat

Machining a cleft to width.

Once in the workshop, the cleft undergoes various machining processes

to be cut into the basic blade shape. The skills involved in machining,
and its importance to the integrity of bat production is why we have
invested so heavily in our workshops. Many companies sub-contract
machining and pressing.

Step 4 - Pressing the Blade

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.

Step 5 - Fitting the Handle

Handle being spliced into a blade.

The handle, a laminated construction of cane and rubber strips , 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 - Hand Shaping

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.

Step 7 - 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.

Step 8 - Binding, Polishing & Labelling

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.
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After all these processg finally we have a complete professional Cricket
Bat
SHOE MANUFACTURING
Stage 1
Pattern cutting marks the first step in the production of a Maison Corthay
shoe. This enables the final footwear to be produced from its original
design. Once the pattern has been prepared, it’s on to the construction of a
wooden frame, around which the shoes will be crafted. The frame provides
the right shape and fitting.
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Stage 2
Next comes the cutting of the leather. The camel leather, which has made
its journey from a government-owned tannery in Abu Dhabi to the Loire
Valley and undergone a special tanning process to make it even softer,
must be cut, in a process known as clicking. Specialist clickers will examine
the material for any defects before deciding which parts to use, with the
finest-quality leather bends kept for the soles and heels of the shoe.
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Stage 3
Once the leather is cut, the sections are assembled and stitched together in
the closing room to create the shoe upper – the parts of the shoe that cover
the toes, the top and sides of the foot, and the back of the heel. Several
processes take place in this stage, such as punching, gimping, side-
stitching, hand-sewing and fitting eyelets for the laces. Each process
requires precision and hand-eye coordination by skilled machinists.
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Stage 4
This step involves the preparation of the rib, which is attached to the insole
and onto which the welt, which runs along the perimeter of the shoe’s
outsole, will eventually be stitched. It is then pulled over the toe of the shoe
by a four-part lasting machine.
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Stage 5
Next stop, the lasting department, where the Arca will finally begin to take
its shape. The upper is tackled onto the last and cork is inserted into the
cavity underneath to provide insulation. It is crucial for the upper to be
correctly aligned, before it side-lasted by hand.
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Stage 6
The shank is added next. This is made of wood and gives support to the
Beech. The rigidity of the arches is ensured by the wooden shanks. They
form the backbone of a fine welt shoe and provide proper support and
shape. The cork is also fixed in place. A natural cork provides the perfect
insulation. It fills the cavity of the desired bottom shape and, more
importantly, its cellular structure adopts the shape and form of the foot like
a cushion and helps to reinforce the insole. It also eliminates any clicks and
squeaks, which can be caused by the shank area. The leather insoles are
now tacked on to the lasts. After the shoe has been fully lasted, the welt is
skilfully stitched through the sides of the upper to the rib of the insole.
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Stage 7
Goodyear-welted construction is completed by attaching the soles and
stitching through the welt. Named for Charles Goodyear Jr, who invented
the machinery required for the process, Goodyear welting is a time-
consuming process, but widely acknowledged as the leading method of
shoe construction. It offers strength and durability, and allows for worn
soles to be removed and replaced with new ones, without affecting the
leather uppers. After attaching the soles, the process of bottom levelling
rounds the soles to the shape of the last. The heels are attached in the
finishing room. They are trimmed and scoured with several grades of
emery paper to create the smoothest of finishes.
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Stage 8
In the very final stages, the soles are edge-trimmed. The soles and heels
are then stained and the edges coated with hot wax to to aid waterproofing
and seal the leather. After that, the lasts are removed, soles are stamped
with the Corthay brand and the insocks are fitted. Before the shoes leave
the factory, they are hand-polished and hand-brushed by the patina artist.
Finally, the shoes undergo a thorough check, before being laced, boxed
and dispatched.