These moulds are inspired by the meticulously constructed paper moulds that were common in all Western mills until the middle of the 19th century. Instead of the traditional mahogany, I use Costa Rican Teak (Tectona grandis), an FSC-certified lumber that comes from sustainably harvested teak plantations grown on former cattle ranches. A favorite of boat builders because of its natural oil content and tight grain, teak is an attractive hardwood that repels water without the need for epoxy or varnish.
My moulds have rabbeted corners reinforced with hidden brass screws. A single round stay supports wing-shaped ribs, which are sewn to an 8-mesh backing wire. A 40-mesh stainless facing wire is sewn to the backing. Thin brass trim, screwed to the mould perimeter, hides and secures the mesh edge. Every mould has a custom-fitted deckle that is shaped for comfort and for proper sheet formation. The deckle corners are strengthened with wood splines. All the wood is rubbed with linseed oil. The finished mould and deckle together have a thickness of about one inch.
