[expand]The layout established felt’s dimensions and thickness. The prepared wool was spread in layers on reed mat or old felt sheet, each layer oriented perpendicular to previous layer creating cross-hatched structure. The thickness was determined by application—thin felt for clothing required few layers, thick felt for yurt walls needed substantial wool accumulation, armor felt demanded extreme density. The felt maker’s judgment was essential—too little wool produced inadequate material, excess wool wasted resources and created unnecessarily heavy felt.
The wetting initiated felting process. Hot water (not boiling but near it) was poured or sprinkled over wool layers, penetrating completely, making fibers slippery and pliable. Some felt makers added soap, increasing alkalinity and accelerating felting, though traditional purist methods used only water. The wetted wool was covered with cloth or mat preventing fiber loss during subsequent handling, creating sandwich of bottom mat, wool layers, and top covering.
The rolling and beating provided mechanical agitation causing fibers to interlock. The entire sandwich was rolled tightly, tied with cords preventing unrolling, then subjected to prolonged rhythmic manipulation. The methods varied: rolling bundle back and forth with hands or feet, beating with sticks, kicking while walking, or most dramatically, tying bundle behind horse and dragging across steppe for miles. The key was sustained agitation—the physical action forced wool fibers to migrate and tangle, their natural scales catching on neighboring fibers, creating irreversible interlocking that defined felt’s structure.
The checking occurred periodically. The bundle was unrolled, felt’s progress assessed by attempting to separate fibers. Early stage felt separated easily indicating continued rolling needed. Advanced felt resisted fiber separation, its fibers thoroughly entangled, suggesting approaching completion. The assessment required experience—stopping too early produced weak felt that would delaminate in use, excessive rolling made felt excessively stiff and difficult to work. The optimal stopping point balanced strength, flexibility, and desired thickness.
The fulling provided final densification. The felt was beaten, pounded, and compressed while still damp, squeezing excess water while forcing remaining air spaces closed. This step transformed somewhat fluffy material into dense, compact felt approaching final properties. The fulling was brutal physical work—hours of pounding and squeezing, arms aching, hands cramping, but perseverance was rewarded with felt whose density and performance justified labor investment.
The drying occurred carefully. Rapid drying caused shrinkage and hardening, excessive moisture retention invited mold growth. The felt was spread flat in shaded location with good air circulation, occasionally repositioned ensuring uniform drying, protected from rain or dew. The drying time varied by felt thickness and ambient humidity—thin felt might dry in day, thick yurt coverings required several days. The patience was essential—rushing this stage ruined otherwise excellent felt through warping or uneven shrinkage.
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