Turning logs into boards by hand is a traditional and rewarding craft that requires patience, skill, and a few basic tools. This process has been practiced for centuries, allowing woodworkers to transform raw timber into usable materials for construction, furniture making, and various other applications. While modern machinery has made milling more efficient, working by hand offers a deeper connection to the wood and a sense of accomplishment. This guide will walk you through the essential steps of how to make boards from logs by hand.
Why Make Boards by Hand
Making boards by hand is more than just a method of woodworking—it’s an art form rooted in tradition and craftsmanship. While modern machines can quickly process timber, hand-milling allows for greater control, precision, and appreciation of the material. It enables woodworkers to preserve the natural beauty of the wood grain and adapt their techniques to the unique characteristics of each log. Additionally, it fosters a sustainable approach by minimizing waste and reducing reliance on energy-intensive machinery. Many woodworkers find the process deeply fulfilling, as it connects them to the rich heritage of woodworking and provides a profound sense of achievement when transforming raw timber into functional and artistic pieces.
Tools and Materials Needed
To successfully engage in woodworking, having the right tools and materials is essential. Basic hand tools such as saws, chisels, and planes are indispensable for shaping and detailing the wood. Clamps are crucial for securing pieces during cutting or assembly, while measuring tools like rulers, squares, and calipers ensure precision. For finishing touches, sandpaper and brushes are necessary to smooth and polish the surface. When selecting wood, it’s important to choose quality timber suited for the project, whether it’s hardwood like oak or softwood like pine. Additionally, adhesives, stains, and protective finishes play a vital role in enhancing the durability and appearance of the final product.
10 Methods How to Make Boards from Logs by Hand
1. Select and Prepare the Right Log for Milling
The process begins with thoughtful log selection. Not all logs are equal, and the success of board-making starts with choosing straight, knot-free, and healthy wood. Species like oak, maple, ash, or cedar are great candidates depending on your desired board use. Once selected, debark the log using a drawknife or bark spud to prevent contamination of cutting tools and improve accuracy. If the log has been freshly felled, let it sit for a few weeks to ease sap loss and stabilize moisture slightly, though full seasoning will happen after cutting. Setting the log on level ground or secured on cribbing provides a steady work platform.
2. Use a Chalk Line or Straight Edge to Mark Cut Lines
Before cutting, you must plan your board layout. Using a chalk line, string, or a straight edge and carpenter’s pencil, mark longitudinal lines down the log to guide your saw. These lines represent where your boards will be sliced and help maintain consistent thickness. Start by squaring one side of the log if possible, which will become your flat reference face for subsequent cuts. This step is particularly critical for hand sawing to prevent deviation and uneven boards. Clear markings keep the process precise and organized, especially as you work through multiple logs or intend to use the boards for fine furniture.
3. Rip with a Two-Man Crosscut or Pit Saw
To begin the actual cutting, employ a two-man crosscut saw or a pit saw—a tool historically used to slice logs vertically into planks. These saws are long, toothed, and meant for rip-cutting along the grain. One person stands atop the log while the other stands below in a pit or trench, using gravity to their advantage. The rhythm must be steady and cooperative. Each stroke removes a thin layer of wood, and it’s common for this process to take hours for a single board. This method, while labor-intensive, is deeply rewarding and produces boards of exceptional character.
4. Use a Frame Saw for Controlled Vertical Cuts
For those working solo or without a pit, a frame saw can be used. It’s a large hand saw mounted within a wooden frame, tensioned to keep the blade straight during deep vertical cuts. It allows for long, controlled strokes with a finer kerf than a pit saw. Frame saws are ideal when processing smaller logs or if you want more manageable equipment. Using a sawhorse or a secure cradle to hold the log steady is essential. This technique offers a more precise cut, especially when combined with careful chalk lining and periodic checking with a square.
5. Hew a Flat Side Using an Axe or Adze
Before sawing, it’s often helpful to hew one flat surface to stabilize the log and create a reference face. Using a broad axe, begin by scoring shallow vertical cuts along the side of the log at regular intervals, then chop away the raised material in between. Follow up with an adze or a hand plane to smooth the surface. This method was widely used before the advent of sawmills to create the first flat face on a log. It not only reduces the effort needed for sawing but also helps in maintaining consistency in board thickness.
6. Wedge and Split Logs for Rough Boards
For a more primitive yet effective approach, use wooden or metal wedges and a mallet to split the log along its grain. This technique, known as riving, works best with straight-grained woods like oak or ash. Drive the wedge into the end of the log, using a maul to deepen the split. Then insert additional wedges along the crack to force the wood apart. While this method yields boards with a rougher texture and less precision, it is excellent for rustic furniture or fencing. The resulting split boards can be cleaned up with a drawknife or plane.
7. Plane and Flatten Boards with Hand Planes
Once boards are cut or split, they will be rough and likely uneven in thickness. Hand planing is the traditional solution. Start with a scrub plane to remove high spots, followed by a jack plane for flattening, and finish with a jointer or smoothing plane for fine-tuning. Using winding sticks and a straightedge helps assess flatness across the board’s length and width. This step is essential not only for visual appeal but also for ensuring the board is structurally sound and stable. Proper planing reveals the beautiful grain patterns that hand-cut wood is prized for.
8. Use a Hand Ripsaw for Small, Controlled Cuts
For smaller logs or detailed resawing work, a sharp hand ripsaw is a useful tool. Unlike crosscut saws designed to sever across grain, rip saws have chisel-like teeth optimized for slicing with the grain. This is ideal when trimming wider slabs into narrower boards. Clamp the slab securely, mark your desired width, and work slowly with steady pressure. Periodically check for square alignment. This technique is ideal for trimming pre-cut boards down to uniform width or turning a hewn slab into panel stock.
9. Dry and Stack Boards with Proper Stickering
Freshly cut or split boards retain a high moisture content and must be dried before they’re used. This is achieved through careful stacking and stickering. Place thin, evenly spaced wooden strips (stickers) between each layer of boards to allow air circulation. Stack the boards in a dry, shaded, and well-ventilated area, ideally under a roof or tarp with good airflow. Weigh the top layer with stones or additional wood to reduce cupping and warping. Air-drying can take several months to over a year, depending on board thickness and wood species, but it ensures dimensional stability.
10. Refine and Square Boards for Final Use
After drying, your boards may need further refinement. Check for warping, cupping, or twist and use a jointer plane or scrub plane to correct them. You can square edges using a shooting board or a hand saw with a miter box. Truing each face and edge makes the boards ready for use in joinery, cabinetry, or framing.
Hand-crafted boards often feature unique character—saw marks, grain irregularities, or tool marks—that lend authenticity and rustic charm. Embrace these elements while ensuring the boards are functional and well-fitted for their intended purpose.
Conclusion
Making boards from logs by hand is a blend of physical labor, time-honored skill, and deep respect for the material. While it may lack the speed and precision of modern machines, the process offers unmatched satisfaction and connection to your craft. Each board tells a story—from the selection of the log to the final plane stroke—and reflects the effort and care put into it. With these ten methods, you have the foundation to start converting logs into lumber the traditional way, preserving a valuable skill that honors both history and the natural beauty of wood. Thanks for reading, and we hope this has given you some inspiration on how to make boards from logs by hand!
