8. Hand-woven denim

Check out our finished piece of handwoven denim. Beautiful blue, naturally dyed indigo yarns, and a luxurious drape that doesn't come from machine-woven denim. While this piece isn't going to necessarily feel like jeans, it sure is gorgeous. 

5. Warping the organic cotton yarns on the loom

Make new heddles for the table loom before weaving the denim

With our warp wound and counted out, we could finally put the warp onto the loom, the last step before weaving. But wait, upon counting, we discovered that there were only about 300 heddles on the loom, meaning we were 228 heddles short! So new heddles had to be made and fitted on the harnesses. This was easy enough, with a tying frame quickly put together with a small board and 4 nails placed where the knots in the heddles should be, and some carpet warp tied into loops around it, and then fitted onto the harnesses. 

Sley the reed with our indigo yarns

Once the loom was set up, the warp could be threaded through the reed and heddles. This particular table loom has the warp wound on front-to-back, so first we were to sley the reed. This meant placing the wound warp at the front of the loom, with lease sticks inserted into the two sides of the warp cross to keep the cross in place. These sticks were lashed to the loom to prevent them from moving and the beater bar holding the reed pulled forward and secured. Carefully going along the cross from right to left, we used a threading hook to pull three yarns through each dent (opening) on the reed. To prevent any accidental pulling of these yarns, yarns that were already threaded were tied at every ten dents (thirty yarns) with a loose slip knot on the backside of the reed.

After the reed was properly sleyed, the beater was released and the loom turned around so the yarns could now be pulled through the heddles. The heddles connect the warp threads with the harnesses that would be lifted or lowered during the weaving process, determining the pattern possibilities. Each heddle held the warp yarn along a vertical axis through an eye and was tied on both ends to rigid horizontal beams that were then connected to pedals or treadles (hand-operated levers at the top). Denim, being a three by one twill, would only use three harnesses, so the fourth was removed and the heddles transferred to the remaining harnesses. 

Threading the indigo yarns through the heddles

Starting from the right side, the little bundles we had tied in slipknots were now untied and one by one, they were again hooked through the eye of each heddle. The heddles were threaded sequentially, one through the first heddle on the first harness, then the first heddle on the second harness, and finally the first heddle on the third harness. Because they were three to a dent on the reed, the order in which these three yarns were selected mattered less than making sure no dent was missed as you went along. Special attention had to be paid to avoid missing a yarn as we went along, since that would result in either the tedious process of starting the heddle threading over again, or cutting the yarn and leaving one dent with less than three yarns, which would create a gap in the weave density. At every six heddles, the yarns were pulled so the ends met at the same length, the threading was double-checked to ensure that the heddles were hanging straight and there were no crossovers, and the ends were tied in a double knot. 

Tighten the indigo warp yarns for weaving denim

Once all the heddles were threaded and tied off, the warp was centered and tied onto the back beam. The lease sticks were removed from the front cross and the warp was uncoiled. The beam was then turned so the yarns wrapped around the beam, with warp sticks being inserted through the entire warp at every 1/3 turn to keep even tension and prevent tangles. The warp was wrapped until only about 12 inches remained at the front.

To tie the warp onto the front apron rod, the general rule is to hold two bundles of six in each hand (four bundles total) and pull until the tension is even. Then, the bundles in each hand are wrapped over the apron stick, coming up from under and behind the rod and then tied in a tight overhand knot over themselves. 

This was first done at both ends of the apron rod to keep it taut. Then, starting from the center and working its way outward towards both ends, we pulled and tied the bundles over the apron rod, keeping as consistent tension as possible and making sure that the reed was centered and all yarns were tied on so they ran straight from the back. Once they were all tied, we lightly touched each section with the back of a hand to test the tension, and tightened or loosened any outliers. When the tension was completely even, the overhand knots on the apron rod were tied into square knots and our warp was tied on! 

Now, with a few cranks of the front beam, the warp was tight from back to front, evenly going through each heddle and reed, and ready for weaving! 

Untangling our indigo yarn

Organic cotton yarn hand dyed in indigo. 

Organic cotton yarn hand dyed in indigo. 

After suffering through days and nights of wrestling with tangled messes of blue yarn on my lap, breaking fingernails picking apart tight knots, turning my hands indigo and listening to the many well-intentioned but condemning suggestions to "maybe give up and start over", "wouldn't it be faster?", and finally the eye-rolling and "good luuuck" said in that singsong tone of incredulity...a month and a half later after the yarn was revealed to be a hot tangled mess, we finally, finally managed to untangle it. 

There were, as with all miserable experiences, some lessons to be learned from this ordeal. The number one being patience. Had I been more patient and double-checked my work when tying the hanks to begin with, they might have remained in the neat, organized loops the hanks were designed for. Had I just been patient and waited to put the yarn on a swift, instead of trying to comb through it with my hands on a table and getting inner loops tangled onto outer loops, we might have been able to prevent the knots that formed. And finally, in untangling the yarn once it's on a swift, one cannot rush it by by tugging on the yarn, which inevitably causes overlapping yarns to tighten on themselves. Nor should one attempt to follow the yarn through loops that are seemingly in the way, as that unintentionally threads a new knot where there wasn't one before.

Because there was no actual knotting occurring in this yarn, at least at the outset. No actual yarn ends crossed over and under each other. Rather, certain looser yarns had fallen over other yarn loops and then been tightened until the yarn at the very bottom couldn't move, though they were all still running parallel. Instead of tugging or dodging a loop whenever the yarn hit a blockage, all one had to do was lightly shake the yarn at the center and lightly loosen the other yarns lying on top to release their hold. Once loosened, the yarn would continue to move along the swift, unwinding as it went along, without causing any disruption in the orientation of the other yarns.

For us, because one of our skeins had gotten hopelessly knotted upon itself, we ultimately had to carefully cut one yarn at a time and wind the loose ends until they hit another roadblock, carefully accounting for all loose ends until finally, one yarn was identified that could go around the rest of the unaffected skein without getting caught up in the knot. Finding this yarn took about a week. Once identified, the winding went more or less smoothly, being careful not to get all the other dangling yarn bundles tangled even more on each other.    

Oops, tangling our indigo yarn hanks

our organic cotton yarn hand dyed in indigo

our organic cotton yarn hand dyed in indigo

With the yarn dyed and fully dry, everything was ready for us to start putting it on a loom. In order to prepare the warp, we needed to first wind the yarn onto a warping frame (also known as a warping board), to measure out consistent lengths in yarn to be tied later onto the loom. As we took our dyed skeins of yarn out to be wound, it became apparent that this was not going to be easy.

I had mistakenly tied the figure eight loops meant to hold the separate skeins together at the wrong places, which means there were yarns from one skein crossing over into another, and when they had been dipped into a dye bath, they had become a whole tangled mess. We tried to salvage it by putting it on a swift. But first we needed to find the ends of the yarn to prevent further entanglement. I had further neglected to tie a different yarn at the ends so that they would be recognizable from a mile away, so needless to say we were looking for a tiny double knot that was dyed, like everything else, blue. Miraculously, after a thirty minute needle-in-haystack search, we managed to find the ends and snipped them open to begin unwinding. 

But it was of no use. The yarn had become so tangled upon itself that every pull of the end caused some other part of the hank to tighten, and the only option we were left with was to painstakingly untangle each yarn until we reached what we guessed to be four yards, and then to cut it off and tie it to the warping board. After two hours, I had tied on five warp yarns. 

Tomorrow I will try and see if the other hanks are any less tangled than this. If not, we may have no choice but to start over from the beginning. 

Oops. Our organic indigo yarns have become tangled. 

Oops. Our organic indigo yarns have become tangled.