A Craftsman's Legacy

>> Legacy is about the things that you can pass on.

You can pass on your wisdom... your skills... >> How about this?

>> Manifold.

>> This down here?

Proper tire pressure would be?

>> 55 PSI.

>> ...and maybe you can pass on something just a little bit more.

The Ford F-150, a proud supporter of "A Craftsman's Legacy."

>> The simple spoon's a tool we all use every day -- so often, I bet you don't even think about it.

Jonathan Simons does.

He's dedicated most of his life to designing and creating wooden spoons.

I'm in Pennsylvania to find out how he got started and hopefully learn how to make one.

>> Hey!

Jonathan.

>> I'm Eric Gorges.

>> Come on in.

>> All right.

A craftsman battles for perfection, never willing to give in or walk away.

I'm Eric Gorges.

I build custom motorcycles using skills passed on by countless generations before me.

I used to work 9: 00 to 5:00, chasing money and titles, and it nearly broke me.

So, I started over.

I decided to work with my hands to feed my soul.

Please join me on a quest to uncover the skills that built our society.

We'll discover what drives the men and women who I call my heroes.

We'll learn their craft and maybe even find some inspiration along the way.

There's a part of you in everything you create, your legacy.

"A Craftsman's Legacy."

You make a variety of different things, don't you?

>> As many as I can.

>> How did it all start?

>> I was at work one day, forgot a spoon to eat my lunch, so I made one.

>> You just made a wooden spoon?

>> It was more of a stick.

>> More of a stick?

[ Laughs ] >> Kind of curved, like... >> Where were you working?

>> I was at a furniture maker in New Hope, Pennsylvania.

>> How long was it from the time you made that first spoon at lunch to you started making more of them?

>> I started pretty much that week.

I had just gotten out of college.

I had a little workshop in one of the bedrooms in the house, and I made some spoons, and I took them down to a consignment shop, and I started selling them there.

>> Yeah, how'd they sell?

>> They sold, and they wanted more, and then I would take them to health-food stores and try and trade them for food.

And then I ran into a salesman, who, for the next year, took them all around and brought back orders for me.

>> Really?

>> He actually taught me how to do wholesale, and to create a product list and categorize the different spoons.

>> [ Laughs ] How many different spoons were you making?

>> I had 13.

I got up to 13 different spoons, but they were made in probably 10 different kinds of wood, like red plum, apple, hickory, cherry, lilac.

I called them "backyard exotics."

>> [ Laughing ] I like that.

>> Because they come from people's backyard.

>> Mm-hmm.

And how long did you do that?

>> I did that for about seven years.

>> By yourself, pretty much?

>> Yes.

Seven years by myself, and then I hired my first helper.

I had been thinking, "How do I make more spoons?"

Because I saw there was a good demand for them.

The first time I went to a national wholesale show, I sold out my year's production in the first hour of the show.

>> Really?

>> Yeah, the buyers were lined up in my booth.

>> Oh, my gosh.

You sold out the first year's production in an hour?

>> Yeah, which was about $10,000.

>> Wow.

>> At that point, I was able to develop some of my best designs and copy them over and over, and then refine them into just the right balance and just the right shape... >> Okay.

>> ...and do them in production so the price was less.

And then I was able to develop and teach other people to make the same thing over and over.

>> Okay.

At what point did your product line start to change?

Because you make all kinds of things now.

You have the different kinds of spoons and ladles and tongs and forks and just all kinds of things.

>> Well, it took years to figure out how to do the inside of the spoon, the inside of the bowl.

>> Okay.

>> Most of my spoons at the start were very flat, and they were more paddles and spatulas.

>> Oh, okay.

>> So, once I developed that technology, I was able to move forward with bigger bowls, and actually come up with a ladle.

>> What do you enjoy making the most?

>> I think it's spatulas.

I use it every day, and just something about the simple curve, working on the angle.

It's very simple.

>> And what about the rest that you made, where you hook the spoon on the side of a bowl?

>> Yeah, we call that the Lazy Spoon.

It was a very popular spoon, and I made a lot of varieties of it.

Rachael Ray's husband called and wanted them for their magazine.

And then, about a month later, somebody from "Oprah" called, and they wanted them on the "Oprah" show.

We had to actually ship them to Chicago overnight.

So we drove to Allentown while we were trying to find FedEx -- and it was before we had a smartphone.

>> Okay.

>> So, we ended up seeing a FedEx truck, and we followed it.

>> [ Laughing ] Oh, really?

>> And we made it there 10 minutes before they closed, and we got it on the truck, and it was on the show the next morning.

>> Oh, my goodness.

>> That was amazing.

>> Did things change for you at that point?

>> Say in six minutes, it doubled the size of my business.

>> Wow.

>> We hired more people.

>> You just brought on more people?

>> And we got more efficient.

>> And you do a lot of work with lasers now, right?

>> Yeah, lasers didn't come till later.

But when we got a laser, I started playing with it, and it reinvigorated my creative energy, and we started cutting out all kinds of different things with it.

So, it gives a nice outlet for my creativity.

>> Now, when you were a boy, were your parents handy and crafty?

>> My father was a preacher, and he worked in the Bryn Athyn Cathedral.

The Bryn Athyn Cathedral is made in kind of a Gothic style, but then all the woodwork inside was very Craftsman style.

The doors were hand-carved.

So, as a child, I would feel those doors, and I just loved the flow of the wood.

That made a big impression on me.

>> It did?

>> And it wasn't till we were lasering out a design, one of our MoonSpoon designs -- it's called the Cathedral design, and it wasn't until that was designed and made that I realized, "Oh, this is because I grew up at the cathedral."

>> Right, right, right.

>> It was like this design burning inside me.

>> Do you look at yourself as a craftsman or as an artist?

>> I think I kind of start with the art, move into how to do it as the craftsman side of it, and then I move towards entrepreneur.

>> Oh!

>> When I'm working on a one-of-a-kind piece, I respond to the grain of the wood, the flow, the thickness.

Everything's different every time.

It's like every cut needs a correction, so you cut it once, and then you fix it.

And then you fix the mistake you just made, and fix it again, and keep cutting until you end up with something that's functional.

I want things to really work.

So, there's the essence of a spoon that is how it relates to the world in its usefulness, and then there's the connection of that to the human.

I just love that connection between the function and then how does it fit in the hand, and how does it connect.

That seems to be so much of our whole process in the world, is how we connect with the world.

And the spoon is like an allegory of that.

>> That's a good way to look at it.

I like that.

So, you think you're about ready to teach me how to make a wooden spoon?

>> Oh, yeah!

>> Yeah, I'm excited.

I've never made one before.

>> All right.

>> [ Laughing ] All right.

>> Let's make one.

>> Let's go down to the workshop.

>> Okay.

>> Because of their simple design, which mimics the shape of our cupped hand, spoons are believed to be the first utensils made and used by humans.

Wooden spoons have been made nearly every place on earth.

Their use and design have evolved according to the needs of the people using them.

The ancient Egyptians had small, intricately carved spoons that they used for religious rituals.

In the 17th century, originating in Wales, the love spoon was a beautifully carved courtship gift that was used as a way for a potential suitor to demonstrate that he had woodworking skills that could provide for his family.

In our modern world, the wooden spoon serves multiple purposes, and Jonathan Simons has thoughtfully crafted a design for every use.

So, we're going to make a spoon today.

>> Yes.

>> Something like this?

>> Like that.

>> Okay.

Not exactly, though.

>> Not exactly.

Every one comes out different.

>> Yeah?

>> Every spoon.

Even when we're trying to make the same spoon over and over, they all come out different.

>> That's nice.

>> Yeah.

>> And we've got a big piece of wood here, so we're going to make a giant spoon with this?

>> No, I'm going to cut it down into a little board.

>> [ Chuckles ] Okay.

But do you normally start with wood like this, like just a piece of the tree?

>> No, I learned early on that I wasn't built like a lumberjack, so I stopped trying to harvest the wood.

And I use the telephone, and they deliver it on a truck.

We get 14-foot boards that are two inches thick, and we cut them down into little, tiny spoons.

It almost seems tragic, but the spoons are so nice to use.

>> Yeah, yeah.

>> So, the tree that's growing just can't wait to become a spoon.

>> So, with this, how are we going to process this to start making spoons?

>> First, I'm going to cut it into a shorter section.

>> Okay.

>> Then, I'm going to rip it into boards.

>> Okay.

So cut it into length, and then rip it.

You're going to go straight through and start splitting it down.

>> Yes.

>> Right?

>> Yeah.

>> And is there anything in particular we're looking for when we're doing that?

>> We're looking to follow the grain.

>> Oh.

>> Because the more we can follow the grain, the fibers, we will have a stronger spoon.

>> Which is important.

>> Yes.

>> You don't want it to break off in your chili.

>> No.

>> Yeah, right.

Okay.

Well, let's get going, man.

>> All right.

[ Saw whirring ] Now, we just made it.

I love what's inside of that.

>> Look at that.

Beautiful.

>> It's just great.

>> We've got a couple boards here.

>> We're ready to make spoons.

>> So, how do we go about finding a spoon in here?

What do you do to find that spoon?

>> I look at the wood, look at it sideways, on the top, follow the grain, and just feel where the spoon wants to be in this.

You want to avoid the knots.

>> Okay.

>> You want to avoid the cracks, and draw it out of the wood.

>> But you don't physically draw it.

>> No, no.

>> You just mentally draw it.

>> Mentally pull it.

>> So, why don't I watch you start, and then I'll see if I can make one.

I usually have a hard time with symmetry when I free-cut things, so we'll see.

>> Well, it doesn't have to be symmetry.

>> Oh, it won't be.

>> Oh, okay.

>> [ Laughs ] >> [ Laughs ] >> Let's get rolling.

>> All right.

[ Machinery whirs, whines ] >> Now, the spoon's going to end up being a lot smaller.

I'm just taking the first cut so that I can see what's inside the wood.

I'm looking at putting the bowl here and bringing the handle in right about there.

And here, I'm just going to take it and give it a little bit of a curve.

>> Look at that.

>> You're ready to try it yourself?

>> Yeah, I think so.

>> All right.

>> I think I'm going to put the bowl on this end.

>> You're going to have to avoid this crack here.

>> Yeah, I was going to come in like this.

>> So exciting.

>> [ Laughs ] I was trying to get a full radius all the way around.

>> Either by coming in here and avoid that.

>> All right, very good.

>> What do you think?

>> Awesome, yeah.

>> It's crazy.

>> Yeah, that's good.

>> Got a little bit of a profile there.

>> All right.

>> Sweet.

Off to the sander!

>> Off to the sander.

>> You've got a ton of sanding gear here.

>> Yeah, we've got a belt sander, ball sander, brush head, and a rough sander.

>> All right.

And the ball sander, I've not seen one of those before.

>> It's a lacrosse ball from high-school athletics.

>> [ Laughing ] Yeah?

>> It's the very one I used when I had my collarbone broken.

>> Really?

>> No, not really.

>> The game-winning one?

>> Yeah, that's right.

>> So, you made this yourself.

>> Yeah.

We glue abrasive to a lacrosse ball, mount it on a motor, let it spin.

>> Fantastic.

And where do we start with all this?

>> Start with the belt sander.

It's the most aggressive, so we're able to make the cavity with that.

And then we move to the ball sander to finish the inside.

>> Oh, okay.

So, we're going to sort of shape the bowl with the belt sander, and then move onto the ball sander here?

>> Yeah, with a spoon, you want to work on the inside, and then work on the outside.

>> Ah, I gotcha.

>> Because the inside's the harder part to do.

>> Oh, okay.

All right.

Well... >> Should we start?

>> Yeah!

[ Sander whirs ] >> So, we start here, because that's where I want the center of the bowl.

You change the angle slightly.

All right.

A little more.

Take out some of the bumps here.

>> Okay.

>> All right, looks good.

Roll it a little over to the top or work off the bottom.

Now, I want to bring it up the handle just a little bit.

So, there we got it.

>> Nice.

>> Now you want to try?

>> Yeah.

>> All right, now comes the real work.

>> Yeah?

>> Grinding all the rest away.

>> [ Chuckles ] All right.

>> I start to hold it in my hand and feel what it's going to be used for.

>> So, what do you think?

>> Well, let me see.

Looks pretty nice.

Looks like a really nice left-handed spoon.

>> A left-handed spoon?

[ Laughing ] There's no such thing.

>> Well, this spoon wanted to be left-handed, so you came up with a left-handed spoon.

Now, my spoon has a right-handed spoon with a left-handed handle.

>> Oh, you're being serious here?

>> Yeah.

Yeah, we make lots of right-handed spoons and left-handed spoons.

>> See, I was thinking this was a little more like caveman style.

>> Well, that's good.

You can use it that way.

We'll sell it that way.

That'll be good.

>> [ Laughs ] So, why are we standing in front of a laser with a propane torch in it?

>> Because this is where the heat is.

>> Okay.

>> The laser is very hot, so I use it as a burning bed for my spoons.

>> Oh, so we're not doing any laser work right now?

>> Not at the moment.

>> Okay.

We're going to torch the spoons?

>> We are going to torch the spoons.

>> And what does that do for us?

>> It makes it beautiful black, and then it gives it a really smooth finish.

>> And how do we go about doing this?

We just take the torch right to it and char it up?

>> Yeah, we just burn it, try not to let it catch fire.

>> [ Laughing ] Yeah, that would be easy.

>> And we'll get there.

>> [ Laughs ] Okay.

All right.

Do we lay them inside or hold them or...?

[ Igniter clicking ] >> We hold them in our left hand and burn with the right.

>> Okay.

>> I'll do one, you do the other.

>> Okay.

>> I work on the inside first.

>> Oh, just like sanding.

>> Yeah, because that's the part you least want to catch fire.

Now, at this point, it's too hot to hold the other side, so why don't you do yours?

>> Okay.

Is this all right?

>> Beautiful.

Yeah, you're doing great.

And you want to take it up the handle as far as you can.

Try to get it nice and even.

Yeah.

All right, now mine's cooled off enough, I hope, so I can hold it.

Then we'll finish up the handle.

All right, now hopefully yours is cool enough.

>> Yeah, we'll see.

>> All right, all right.

Let's not get carried away.

[ Laughs ] >> So, these are just about done.

>> They are.

Let's take them over to the sander... >> Back to the sander?

>> ...and finish them up.

>> Okay, cool.

I'll follow you.

>> All right.

[ Sander whirs ] >> Last step, eh?

>> Last step.

Wait, two more.

>> Two more steps?

>> Three more.

Three more steps.

Now, here we're putting this decorative line right there.

>> That's what you're doing now?

>> Another decorative line right there, just real careful.

Give it some stripes.

>> Oh, look at that!

>> Put one at the top here.

>> So, this is just making it look good, right?

>> Yeah, gives it a little zip.

Now, this one, I want to follow down around the edge if I can.

Carefully there, and then this side.

>> Very nice.

>> And that's it.

We're ready to brush-head.

>> Oh, we're gonna use this next?

>> You want to do yours?

Yeah.

>> Yeah, yeah, yeah.

>> Let's do yours first.

>> All right, so you're going to start doing that?

>> Should I start?

>> Yeah!

>> All right, so we're just going to blast away at this.

>> What does that do?

>> This gives it a polish.

It takes off the loose charcoal.

[ Machinery whirring ] >> How's that?

>> Nice.

All right.

So you just want one stripe down the side and around?

>> I think so.

>> That looks good.

All right, now you just need to brush-head it.

>> Okay.

[ Machinery whirring ] So, you said there's three steps.

What's the last step?

>> All right.

One more step.

We've got the spoon wax.

>> That's this stuff?

>> Yeah, hand me that bottle.

>> Okay.

>> Open it up.

This is beeswax and coconut oil.

>> It's your own special mixture?

>> My own special mixture.

>> There, hang onto that.

>> And what's this do?

>> What this will do is bring out the color, what we're doing.

Get it all wet with this.

>> Ooh, look at that.

>> Yeah.

>> Wow, look how rich it looks.

>> So, now it's all shiny, and then we can dry it off.

>> How often do you have to wax it like this?

>> Every other month, or when you have company.

>> Yeah, when you got company, you want to show them off?

>> Yeah.

>> [ Laughs ] Look at that.

>> So, let's see.

>> Wow!

>> Yeah, nice.

>> Wow, yours looks really cool.

>> Yours has a very original shape to it.

>> [ Laughing ] You think so?

>> Yeah, it's nice.

We'll publish that next.

>> What a great time.

>> Thank you very much.

It was awesome.

>> I had an awesome time.

Look at that.

>> Yeah.

>> Might be a new design for you.

>> Yeah, I'm sure it will be.

We'll put it into our -- We'll have to send you a royalty.

[ Both laugh ] >> I say we go use them.

>> Yeah, let's go use them.

>> I'd never made a spoon before, and I found the process incredibly fun.

I'm so often reminded that you have to live life with your eyes open and be willing to take chances.

You never know what's waiting for you around the bend.

Jonathan's life might have been very different if he hadn't needed a lunch spoon many years ago.

>> Legacy is about the things that you can pass on.

You can pass on your wisdom... your skills... >> How about this?

>> Manifold.

>> This down here?

Proper tire pressure would be?

>> 55 PSI.

>> ...and maybe you can pass on something just a little bit more.

The Ford F-150, a proud supporter of "A Craftsman's Legacy."

>> To discover more about "A Craftsman's Legacy" and the craftsmen we feature, please visit our website.

And you can also follow us on social media through Facebook, Twitter, and Instagram.