Below is the process every handmade cricket bats goes through:
1. Choosing the cleft
There are many factors that we must consider when choosing the cleft for each individual bat. The main two would be the chosen grade and weight of the bat.
As each cleft is delivered in varying lengths and volume, we standardise each cleft into a blank. This gives us the weight information we need when making a light or heavy bat or a traditional profile or concaved profile.
2. Machining the cleft
Both ends of the cleft have been dipped and covered in a wax to prevent them splitting during the drying process. These ends are cut using a drop saw. At this stage we check for any abnormalities in the willow structure (e.g. storm damage).
Each cleft is then cut to a little over the regulation width of 4.25 inches using a powerful table saw. The apex angle (back of the cleft) is then cut to a standard size. We then plane the face to determine the grain structure which is used to determine the grade of the bat.
Finally the cleft is cut. Each cleft to 26 inches in length to create the 'Blank'
3. Grading
Once the blank is created the cleft is graded.
The blanks are graded on grain structure and density. The higher the grade the better the grain structure and lower the density.
4. Facing
Facing is the process of preshaping the face of the blade. This is done on a spindle moulder with a custom cutting blade to match the profile of the roller on the bat press. This process is vital to minimise/eliminate any pressing cracks during the pressing process. We have several different face profiles and press rollers.
It also highlights any blemishes in the grain that may downgrade the original grading.
5. First press
Having been preshaped the face is ready for its first press. The face is sprayed with a solution to minimise any chance of pressing cracks. Its then fed into the press where the face is submitted to an increasingly higher pressure on each pass. During this stage the fibre structure at top part of the face is compressed. It is at this point we begin to transform an unresponsive cleft into a high performance cricket bat.
6. Splicing the blade
In order to fit the handle we must first cut the 'V' into the blade. We do this using a customised table saw. At this stage we need to decide which end is best suited for the handle and which is best for the toe. At the toe end we are looking for straight grains that run front to back (strongest) in combination with a clean hitting area (minimal blemishes and straighter grains). The other end is then best suited for handle placement.
7. Cutting and fitting the handle
The cane handle is cut on a table saw using a specialist jig that matches the cut to that of the 'V' in blade. The handle is 'dry fitted' (without glue) to check the fit. The fit should be tight enough that you should be able to use as if it had been glued! Precision engineering!!
Once happy with the fit a layer of strong wood glue in the V and the handle. Great care is taken to align the handle, it is then clamped and left to dry for at least 24 hours.
8. Shaping the shoulders
The basic shape of the shoulders are pre-shaped using a spindle moulder and specialist jig. Here we can set the handle length from anything from Super Short to Long Handle.
The final shoulder shape is finished at a later date by hand by a batmaker.
9. The press
Perhaps the most important stage in the whole batmaking process!
Here the batmaker needs to take into account the individual characteristics of each cleft. As each cleft will respond differently during pressing, the batmaker will continually check the responsiveness using a cricket ball. There is no scientific method to the 'perfect press' and is judged solely by the batmaker. The reason its referred to as the 'Art of Batmaking'.
During this process the blade is also bowed using a specially designed press 'bed'.
10. Shaping
This is where the skill of our batmaker comes into play. By using a number of handtools (drawknife, planes, spokeshaves and rasps) our batmaker can create almost any profile. This is the most time consuming stage of the batmaking process.
Here there are a number of factors to consider - finished weight, balance/pick up and the selected profile.
At this stage the shoulders and handle and finished,blended and the toe shape is cut.
11. Finishing
Again another time consuming stage of the process. Here the bat is sanded through 7 different grits of sandpaper to refine the shape and provide a high quality finish.
The handle is then bound using ultra strong Rayon twine to add strength to the handle. As standard we apply a rubber toe guard to all our bats to minimise moisture damage.
The whole bat is then given a polish using a specialist wood polishing compound. This closes the grain and helps maintain a good moisture level to the new bat.
12. The end product
The final stage is to apply a grip and stickers.
In the space of a few hours an unresponsive cleft of English Willow is turned into a stunning high performance cricket bat.
A full range of handmade cricket bats and softs are available via The Cricket Boutique website.
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