Process
The wood is bought in an open market. The most common wood is teak (
sag) or (
sag saghwan) preferred because of its durability and resistance to termites and decay. It is locally known as (
sag2 patli). Despite its durability, the wood is soft and easy to carve. It is also fibreless so especially suitable for fine work. It is bought from the forests of Southern Gujarat.
When bought the wood is in uneven pieces called (
wadh). It is stored in a dark enclosed space for up to one year. Once the wood is ready the edges are shaped with the saw, chisel and adze to give it the desired shape - oblong, square or round, depending on the design. The surface to be carved is filed and smoothened by grinding on a rough stone on which is spread fine river sand and water. The shaped smoothened block is known as (
kaplo.
The (
kaplo) is now ready for the design to be traced on its surface and carved. For any design two types of blocks are carved today: the main block with the outline called (
rekh) and the subsidiary or relative blocks for each colour called (
data3). They are both carved in relief.
The smoothened surface is coated with the layer of white chalk to aid definition and visibility of the traced design.
The design is first drawn on paper. This paper is fixed to the whitened surface of block, held in place with nails. Using a fine tipped or pointed chisel the design is perforated onto the block.
Once the design is traced onto the block, the negative spaces are carved or gouged using a variety of different shaped and sized chisels. If the spaces to be removed are vast, a hand drill is used. Once the block has been carved the block makers finish by engraving a nail shaped point, (
mokh), on the right hand corner of the block. This enables the printer to precisely align the blocks while printing.
The four sides of the block are sloped, narrow at the top slanting outwards at the base where the design is carved. In the case of dense designs such as floral patterns or closely carved designs holes are drilled through the block to allow trapped air to release and thus ensure air bubbles don't smudge the print or spread the colour. These air passages are called (
pavan-sar).
The handle (
chhado) is either carved from the block or attached later. The first is more durable and also more expensive.
After the carving is complete and the block is ready it is placed in groundnut oil for a couple of days to season the wood and protect it from climatic changes and moisture. This ensures the block doesn't warp through repeated use. It takes up to three days to carve a block set of an intricate design.