Craftsman

Craftsmen (male, female, or other) make quality goods. They make better quality goods than folks that are just out to make a buck.  Hobbyists may actually produce higher quality objects, because they are not limited by resources.  That is, a hobbyist can put unlimited time and resources into an object, but craftsmen must keep the cost of objects within the price range of their clients.  Craftsmen produce the best possible product at the most reasonable price, all things considered.


If  someone needs a warm object, then a craftsman knitter will knit an object that is as warm as is required.  If someone needs a durable object, then the craftsman knitter will knit an object that is a durable as it required.  If someone needs a lace christening gown, then the craftsman knitter will knit an object that is elegant enough to uphold the status of the family. Along the way, for each product, the craftsman will make the compromises needed to meet the requirements including cost and schedule. The craftsman can work to a bid/plan/schedule so the cost of the object is as agreed with the client, and the craftsman does not lose money on the project.


Most modern spinners see spinning as a hobby.  They do not care about the cost of the yarn that they produce, or speed of production. And, they are not interested in making better yarn, they only want soft, pretty yarn.  


In contrast, I see spinning as a craft. I want better yarn. I want stronger yarn, I want more flexible yarn, I want more durable yarn and so forth.  And, I want less expensive yarn. I want yarn that has fewer man hours invested in it. I put a lot of effort into working out how to spin faster with less effort. I want yarn that that is just as good but is made from lower cost fibers. That is, I seek to find better fibers at a lower cost. And, I seek yarns that require less fiber, for the same warmth, durability, or strength.  Every spinning project that I do has requirements, schedule, and budget.  When a spinning project does not meet its requirements, schedule, or budget, I pull the plug on it. 


I started spinning because I was a knitter, and I was not happy with the available mill spun yarns. I wanted better.   When I started spinning I was told that it was not possible to hand spin the  worsted spun, 5-ply sport weight yarns, called "gansey yarn".  I was told these yarns had never been hand spun.  It took me 9 months before I was hand spinning such yarns, but the process was so slow as to be impractical.  The yarns I was making were better than mill spun, but they were too expensive.  I had to work out how to make them less expensively.  The obvious solution was to spin faster.  Today, I spin much faster.  That means that my yarn is much less expensive.  I like better yarns that are less expensive.


The first step to spinning faster was to understand differential rotation speed (DRS) as discussed in Alden Amos and the Victorian authors. DRS allows the flyer/bobbin assembly to run at much higher speed, and it changed the nature of the drafting, allowing true worsted yarns to be produced much faster. Part of this step was learning different spinning techniques that allowed me to take advantage of DRS. This really was an effort. This development of other spinning techniques was perhaps the single most important aspect of the spinning faster process. 


The second step was to have Alden Amos make me faster flyers.  I considered having him make me a custom wheel, but the Ashford Traditional drive wheel actually produced more speed than the wheels Alden was making at the time.  That is, an engineering analysis selected the Ashford drive wheel over the Alden product.  It was not a capricious or sentimental decision.  Part of this step was the development of "gang whorls" so that as the effective diameter of the bobbin changed,  I could change whorls rather than stopping to wind off.  I had to design and fabricate the gang whorls. This facilitated the production of longer, continuous singles.


The third step was to make an accelerator for my Alden Amos/DRS/Ashford hybrid.  Again it was an engineering analysis.  It was not a capricious or sentimental decision.  The result was the accelerator/Alden Amos/DRS/Ashford hybrid with advanced drafting technique.


The net result is that my wheel spins woolen singles between 2 and 4 times faster than any  wheel on the market.  My wheel spins worsted singles between 3 and 10 times faster than any wheel on the market.  This was not an accident. It was attention to detail, and doing the engineering correctly.  It was understanding the technique so I could make the required tools.  It was understanding the tools, so I could develop the technique.


Since spinning/twist insertion is the single largest cost in spinning, my yarn is much less expensive than other hand spun. I (the knitter and weaver) is the customer for I (the spinner).  I (the knitter and weaver) like the lower cost of the faster spinning. I (the knitter and weaver) like the shorter delivery times for the faster spinning. All around, I like the faster project development and production cycles. 


This allows me to (inexpensively) dream-up, produce, and test yarns that are not made by mills and which I have never seen before.  I learned to make more flexible yarns.  I learned to make stronger yarns.  I learned to make more durable yarns, and so forth. I would never have had time for this experimentation if I had to spin as slowly as most spinners spin. Without DRS, you will never really understand sock yarn. 


I can plan an object, spin and test samples of a yarn that I have never before spun, and then spin and produce the object, all in a reasonable time frame. I (the knitter and weaver) know in advance what the cost of the yarn will be that I (the spinner) will produce for the project. 


I am a craftsman spinner with just one rather demanding client.  Myself.  If I spin better and faster, then I improve my product and lower my costs.  Then, I am happy.

Warmth, again and again

If you want real warmth in clothing, it needs to block air flow like a fine bed sheet.

With knit wool that means lots of twist in the yarn, and yarns knit tightly together.

Lots of twist means very fine plies. For most things, I like singles of ~5,600 ypp.

Then I do not ply yarn very tightly, so that as yarn is knit, the yarn deforms and "fills" all gaps.

The commercial yarn that this concept is built on is the old Lions Brand Fisherman's Wool.  This yarn is no longer made. Production was moved to China, and the new  Lions Brand Fisherman's Wool is different.  The new Fisherman's Wool is much more pleasant to knit, but the resulting fabric is not as warm or durable.

To block air flow through the yarn, the wool fibers must be between 20 and 40 microns apart.  Closer and they tend to conduct heat. Farther apart and air flows between the fibers carrying heat.  Keeping fibers that close together takes a lot of twist.

For wet weather, I like long wool, spun worsted at 5,600 ypp.  Twist is about 9 tpi. These singles get loosely plied up into a sport weight (1,000 ypp) yarn.

Once you get below freezing, things can get really cold.  There, I like fine wool, spun woolen at 5,600 ypp and 12 tpi. These get plied up into 5-ply at 1,000 ypp or Aran weight at 500 ypp for Arctic  (or Antarctic) conditions.

Ok, these yarns are a bit of extra work, but they are warm, and nothing is worse that being really cold.

The the yarn needs to be knit so tightly with fine needles, so there are no gaps in the fabric.

If you knit with 2 or 3-ply yarns there will not be enough twist to hold the individual wool fibers close together and the wind will blow right through the yarn.

If you use a 5-ply with enough ply twist to hold the yarn round, then there will be gaps between the yarn and the wind will blow through the fabric carrying heat away from the body.

Hand spun, hand knit fabrics can be so warm that they feel like magic.  Most do not make the cut.

Fiber prep for high speed woolen

Good spinning requires good fiber preparation.  Spinning very fine and very fast requires near perfect fiber preparation.

My first fines were all worsted, so early on, I climbed the learning curve for combing wool.

Now that I need fine woolen spun singles for weaving, I am climbing the woolen prep learning curve.  It is just as long and steep, as the worsted combing learning curve.  For a long time, I would divide a batt from a drum carder length-wise, and call  what I spun from that "woolen".    Well, it was more woolen than the worsted singles I spun for ganseys.  It was/is  really semi-woolen.  Spun slowly, it could be mostly woolen and that was good enough for my needs.  And, in fact I preferred that semi-woolen yarn because it was denser, warmer, more durable.  It was/is a very nice knitting yarn that I still like.

Now, I am thinking bout woven fabrics that are "fulled".  And, fulling requires true woolen spun weft. A lot of it, so to get enough of it to be useful, I have to spin very fast.

To spin true woolen, the fiber prep must be carded and then rolled up into a rolag. Spinning fine and fast requires a uniformity in the fiber prep that one is not going to get with hand cards. If you are spinning fast, you need high uniformity from throughout the rolag and from rolag to rolag.  This kind of uniformity requires blending with drum carder.  If you try to spin rolags from hand cards fast and fine, there will be break-offs that will slow you down, until net productivity is higher simply by spinning much slower so that one has some time to adapt so that there are fewer break-offs.

If you must spin fine and fast, you will need the uniformity in you rolags that comes only from very good fiber prep tools. Details matter.  I had been rolling rolags on 3/8" acrylic cores.  Henry Clems suggested that I use use  a 1/2" birch core. That 1/8 inch in diameter, and difference in texture matters.  Half-inch birch is better than half-inch acrylic.  Half-inch birch is better than 3/8" birch. And, 3/4" is too big.  And, if the cores make that much difference, the quality of the carding cloth makes more difference.  Anyway, it turns out that making rolags is a major art from.

These days, Henry and Roy (Clems and  Clems) are the smartest guys on woolen fiber preparation, and they make the best tools for fiber preparation.  (This does not mean that I think 1/2" birch dowel is the very best possible rolag form in the world, but I would agree that it is likely the most cost effective.) These days, their drum carders and blending boards are without equal.   At this point they have hit a nice compromise between the makers of the tools using the tools on a daily basis, and industrial production techniques to achieve outstanding uniformity and quality control at a reasonable price point.   They have gotten to the point where they are starting to have a waiting list.  At this point the waiting list is only a few days, but if you are going to need fiber prep tools this summer, order now.

If you know that you only want to spin one kind of fleece, then one of the drum carders with changeable drums makes sense.  However, I spin about equal parts long wool and fine wool, and I like being able to card both of them on the same carder.

A bit off topic, true woolen requires more twist per inch  than worsted.  The difference is small at low grist, but at  higher grist, the difference is about 50%.  If you want to spin fine, and have a slow (low ratio) wheel, then spin worsted.  I find spinning worsted fines to be reasonable on a slower wheel, but spinning woolen fines on a low ratio wheel is always a long, slow, slog.  Spinning fine is made much easier with a very fast wheel.  Fine yarns that were very difficult on a slow wheel become easy on a fast flyer.  Fine yarns that are easy on a fast flyer are much more difficult on a slow flyer.  This is true at, and well beyond, the spin count.  

Spinning more Hanks

I am in this for the yarn.  I want better yarn.  That means hand spun.

From the start, I wanted my yarn fast.  I was in this for the yarn, not as a way to pass time.  I was willing to put in the time that the chore of spinning demanded, but I did not want to put any extra time into spinning.

I came to spinning knowing how construction professionals worked. They had good tools, they knew how to use them, and they worked rapidly with no wasted motions. They did the job, and then they went on to the next job.  Spinners on the other hand seemed intent on slowing the work process.  Spindles were designed with large whorls so they spin slowly.  Spinning wheels were designed to spin slowly.

Spinners are in denial.  They say, "No, my wheel is fast."  However, they do not stop an think that flyer/bobbin speed is limited by power transfer through the drive band and Scotch Tension systems brake the flyer/bobbin assembly, and thereby reduce the over-all rate of twist insertion.  Then, they have double drive systems that inherently require drive band slippage.  If there is slippage, then the flyer/bobbin assembly is not going as fast as it would without slippage.  For the last 50 years, spinners have been favoring wheels that had SLOW built into them, and wheel makers built what the market demanded.

Spinners say, "These are traditional designs!"  Ok, traditional designs for what?  Linen! The long fibers of flax need a slower speed, and there were a lot of old linen wheels around.  People assumed that a spinning wheel was a spinning wheel, and used old linen wheels as the design prototype for wool wheels.  So what is the difference between the design of a good linen wheel and a good wool wheel?  The linen wheel wants less speed, and the wool wheel wants more speed.  Scotch Tension systems are a logical engineering choice for a wheel designed for linen. They are less logical for a wool wheel. They are not at all logical for spinning cotton.

A traditional wheel design for woolen spinning is Irish Tension. There is no additional braking to slow the flyer/bobbin assembly.  There is no drive band slippage to slow the the flyer/bobbin assembly. The mechanism is simple to make and inexpensive. If you wan to spin medium woolens (30,000 yd/lb and less), bobbin lead is a very good and traditional approach. It is simple and easy to set up. And yet, I remember the feeling of rebellion, when I first tried IT.  Everyone was telling me that most spinners were much happier with ST.  And, yes, IT with the big Ashford flyer does have a very strange feel to it. The sudden increase in take-up at higher speed is very disconcerting for the beginner who is not forewarned.   The beginner (with a big flyer) says WTF, and abandons the concept. The beginner with a small flier feels no take-up and says, WTF and abandons the concept. The ST friction brake provides a steady take-up pressure as speed increases that is easy for the beginner.  While the IT takeup is a cube function that is small at lower speeds, and then increases very rapidly at high speed.   With the big Ashford  fliers, IT does produce excessive take-up pull when one tries to spin fast (more than ~800 rpm).  However, a small flier such as AA's #1 flier produces very reasonable take-up tensions at speeds in the range of 1,800 - 2,200 rpm. On the other hand take-up at speeds less than 1,500 rpm is negligible. At slow speed, one can spin very fragile yarns or make pig tails. For conventional yarns, one either spins fast or it does not work. The AA #0 flier running in IT generates reasonable take-up at speeds in the range of  2,400 - 3,200 rpm.

For the expert with a flyer that has a low aerodynamic cross section,  that low take-up at low speed and high take-up at high speed is a very powerful tool.  The expert can adjust take-up by altering the bobbin rpm by treadling slower or faster. The take-up adjust is precise over a wide range, fast, and does not require the hands to leave the yarn.  All of which  is important when yarn is running through your fingers at 10 yards per minute. However, the spinner much be prepared spin fast, and know that slowing down will stop take-up before the bobbin stops.  This is a set of skills that have fallen out of spinning lore.

Now look at the literature.  Do the experienced spinners warn the beginners? Why not?

What if one wants to spin worsted fines (30,000 to 48,000 ypp)? Fines require some 20+ tpi. Scotch Tension systems will get you there, but it is clumsy and very, very slow.  IT is faster, but it gets very delicate as the flyer is pulled by a fresh yarn of only 20 fibers.  Modern double drive with slippage is a fraction better than ST. Differential Rotation Speed Double Drive is the best engineering design for spinning yarns in this class, but one must prepare and fabricate a specific engineering design for the grist. This is worthwhile if you plan on spinning many miles of a particular grist. Then, these yarns can be spun as fast as they can be drafted, and well prepared fiber can be drafted very fast.  Traditionally, hand spinners did spin fines as a commercial product.  Here, "commercial product" means the yarns were spun by hand rapidly.  Differential Rotation Speed Double Drive has no equal for hand spinning worsted fines.

I spin yarn as I need it. I benchmark how fast I spin, so that I can evolve and improve my spinning.  I do not care how fast you spin, but I do care how fast I spin. I want to make sure that I am spinning at a reasonable rate.  If others are mired in myth and cannot believe what I do, that is not my problem.

My problem is to make the yarn that I need, in the time that I have.