How Japanware was made
The Allgood family tried to keep the process of japanning metalware a secret. Below gives a reasonable idea of how it was done, however we still do not know for certain.
- First the iron bars were rolled into thin sheets.
- The iron sheets were then cleaned and dipped into hot tin, which gave them a thin rust-resistant coat.
- The sheets were then dipped into fermenting rye, which acted like an acid. This cleaned the sheet thoroughly so that it could be decorated.
- The sheets were then cut into strips, which could be shaped into various items. We do not know what kinds of tools were used to shape the items, but it is possible that they were similar to the ones used by silversmiths today.
- A coat of varnish made from a mixture of linseed oil, umber and 'uthrage' (a form of coal dust) was then applied, and the item was baked in an oven which transformed the varnish into a hard, shiny, black surface.
- The article was then decorated. Sometimes a tortoiseshell finish was given to it before decorating.
- Numerous coats of varnish were then applied.
- The article was baked again, giving it a very hard-wearing surface.