Meet a Kakuri Craftsman: Kanai Woodworks' Plane Maker
Kanai-san, 80 years old at the time of the interview, is a seasoned plane maker with over 60 years of experience crafting plane bodies. He began his journey at the age of 15, working under his father, who had been in the craft since the Meiji era. As the second-generation artisan, Kanai-san initially specialized in making planes for professional carpenters, including large, small, and specialty planes. At 45, he started collaborating with Kakuri to create planes designed for beginners, ensuring these tools were not only affordable but also easy to use. Over the years, Kanai-san has refined his manufacturing process to make the planes more accessible while always maintaining their superior quality and craftsmanship.
Understanding the Importance of the Plane Body
Crafting a Plane Body to Completion
1. Choosing the Right Material and Wood Characteristics
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Insight In traditional carpentry, the plane is often said to receive the best parts of the wood, followed by the hammer and the chisel. Kanai-san explained, “We use wood that is harvested in the colder months. After it’s cut, the material is delivered to us in April, and it undergoes a natural drying process over the course of a year. It’s only after this long drying period that we can begin using the material. This slow drying ensures the plane body remains stable and doesn’t warp due to moisture.” |
2. Shaping the Wood: The Art of Precision
Once the oak is properly dried, it undergoes kitori, or the shaping process, where it’s cut to the dimensions of the plane body. Kanai-san emphasized the importance of looking at the wood grain during this step. “It’s important to determine whether the grain is running with or against the fibers. If you cut against the grain, it can cause the surface to splinter, and you won’t get a good result,” he said.
3. Drilling the Holes
At this stage, rough holes are drilled into the plane body. Kanai-san explains, “I determine the right location and angle based on the wood grain, ensuring the holes align with the width of the blade. The depth and angle are adjusted carefully as I go along.” While this task is now done using machines, Kanai-san shared that when he first started making planes, it was all done by hand with a large chisel and a hammer.
4. Carving the Groove for the Blade
To ensure the blade fits perfectly, a groove is carved into the plane body. Since the blade’s thickness differs between the tip and the head, this process is done in two stages.
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Insight Kanai-san explained, “I order a large batch of blades at once, sorting them into 47 different categories based on their thickness and angle. By doing this, I can efficiently carve each plane body at the correct angle for each blade.” This method allows Kanai-san to work more efficiently and precisely. |
5. Drilling Pin Holes
At this point, holes are drilled into the side of the plane body to secure the chip breaker with a pin.
6. Widening the Blade Mouth
The mouth of the plane is widened from the underside to ensure the blade can extend properly. Kakuri’s plane bodies are designed with a slightly larger mouth, making them more beginner-friendly. “This design helps prevent shavings from clogging up the mouth during use,” Kanai-san explained.
7. Fine-Tuning by Hand
With the rough shape in place, fine adjustments are made to the internal angles and grooves of the plane body. Kanai-san uses a chisel to carefully refine the fit of the blade, making small adjustments as needed. “I adjust the angles and the grooves little by little, checking the blade fit after each change,” Kanai-san said. “I also use chisels and saws to refine the corners that the machines can’t reach.”
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Insight Kanai-san also shared an important tip: “It’s crucial to pay attention to the wood grain as you work. If you cut against the grain, it can cause the wood to splinter.” He uses around 20 different chisels and saws, making small, precise cuts at delicate angles. Since oak is a tough wood, the fine-tuning process can take up to 30 minutes per plane body. |
8. Final Touches and Adjustments
The final step involves smoothing and refining the surface of the plane body. Kanai-san uses a rasp to smooth out any rough spots and rounds off the edges. As always, he keeps a careful eye on the grain to avoid cutting against it.
Kanai-san’s Journey as a Plane Maker
Kanai-san, now the second-generation plane maker, recalls that his journey began at a very young age. “When I was in elementary school, my father would teach me how to practice drilling holes with a large chisel,” he said. By the time he graduated from middle school, he had already mastered the skills of a full-fledged craftsman. One of the most challenging tasks back then was making the kiwa-ganna (edge planes), which are used for trimming the edges and corners of wood. These planes require a high level of skill for fine finishing work, and Kanai-san’s expertise allowed him to produce them in large quantities, which was no small feat
From Professional Planes to Mass Production
In the beginning, Kanai-san focused on creating high-quality planes for professionals. But as demand for Kakuri products grew, he realized the need to scale production. So, he took a different approach and introduced some innovative changes to the manufacturing process. “I wrote out the entire production workflow and found ways to incorporate machines to help us work more efficiently. This allowed us to increase productivity and reduce costs without compromising quality,” Kanai-san explained. This shift wasn’t just about efficiency—it was driven by his desire to bring exceptional Japanese planes to the hands of more people.
Crafting Tools with the User in Mind
One of the things that sets Kanai-san’s work apart is his focus on making planes that are easy to use, even for beginners. “I always think about how to make the tools more user-friendly. For example, I designed the blade opening a bit wider so the shavings don’t get stuck. I’m constantly thinking about how to improve the design to make it easier for everyone to use,” he said. Above all, his top priority is ensuring that even a beginner can feel comfortable using the plane. “When I make a plane, I always have the person who will use it in mind.”
FAQ for Woodworking Enthusiasts
What’s the Difference Between Japanese and Western Planes?
Western planes often feature a handle, and their overall structure is quite different from Japanese planes. Western planes are made with a metal body, and the blade is adjusted using screws or handles. While these planes are less likely to lose alignment, adjusting them when they do go out of whack can be quite difficult. Additionally, Western planes are typically pushed to use, which is another difference from Japanese planes.
On the other hand, Japanese planes have wooden bodies, which can be affected by changes in temperature and humidity. As a result, they need to be adjusted each time you use them to maintain optimal performance. The blades, made of steel similar to that used in traditional Japanese swords, deliver excellent cutting performance when properly sharpened.
For tips on how to use a Japanese kanna, this video can be a great reference:
How to Use a Japanese Hand Plane: Mastering the Kanna
What’s the Best Way to Store My Plane?
Moisture is one of the biggest culprits when it comes to warping wood, so it’s important to store your plane in a dry environment. Keeping it away from damp places will help maintain its shape and performance for a long time.
Kanai-san’s Thoughts on the Future of Craftsmanship
At 80 years old, Kanai-san has made the difficult decision to close his workshop this year. After decades of perfecting his craft and supporting the fine woodworking tradition, he now faces the challenges of a changing era and a shortage of successors. “It’s become clear how difficult it is to pass down the skills I’ve worked so hard to perfect, especially with the shortage of craftsmen,” Kanai-san shared. Although he has always poured his heart into making tools that are accessible even for beginners, he expressed a strong desire at the end of the interview: “I want more people around the world to experience Japan’s excellent planes.”
“My hope is to see Japan’s fine planes used by people all over the world. It brings me great joy to think that our tools won’t just be used by a few artisans, but will reach the hands of many, crossing borders and bringing craftsmanship to people everywhere.”
Kakuri’s Commitment to Craftsmanship, Walking Hand-in-Hand with Artisans
At Kakuri, we feel a deep sense of responsibility to carry forward the skills and traditions passed down by artisans like Kanai-san. We are committed to addressing the serious issue of the lack of successors, and as part of this effort, one of our employees is currently training under Kanai-san to learn the craft firsthand. Kakuri values the wisdom and techniques of Japan’s traditional tool-making and aims to integrate them into modern craftsmanship. The spirit of thoughtful design and the value of taking time to craft tools that will be cherished for generations is something we want to pass on to the future. Through our work with artisans, we hope to continue sharing not just the tools but the passion of the makers across generations.
