The making of a Khu Khu hand-fan in seven Steps

Making a hand-fan in the traditional way is a fascinating, long and complex process. In order to shed some light on this wonderful artistry take a look at the following seven steps for a better understanding of how it works.

Step One - Wood heated in an oven in a block

All hand-fans start out as a humble block of wood. We use a range of woods from beech and birch to luxury dark woods such as mongoy. A small block of wood is placed in a furnace to dry it out, making it amenable for step two.

The making of a Khu Khu hand-fan Stage 1
The making of a Khu Khu hand-fan Stage 1

Step Two - The block of wood is placed in a cutting machine

This machine cuts the whole block into very fine pieces. These sheets are collectively pressed down with weight to avoid warping. 

The making of a Khu Khu hand-fan Stage 2
The making of a Khu Khu hand-fan Stage 2

Step Three - Wood pieces cut into smaller rectangular shapes

Before the pieces take on their final 'fan' shape, they are cut into more manageable rectangular shapes with a special tool. 

The making of a Khu Khu hand-fan Stage 3
The making of a Khu Khu hand-fan Stage 3

Step Four - A hole is punched into the thin rectangular pieces for the rivet "eye"

This is where the rod of the rivet (pin) will pass at the end of the process. 

The making of a Khu Khu hand-fan Stage 4
The making of a Khu Khu hand-fan Stage 4

Step Five - The rectangular pieces become fan-shaped

The rectangular pieces are placed next to a block of wood with a surface that takes on the form of the hand-fan. When the sanding machine moves along this block, it polishes down the rectangular pieces so that they too take on the right shape. 

The making of a Khu Khu hand-fan Stage 5
The making of a Khu Khu hand-fan Stage 5

Step Six - Trimming the sticks where the fabric will go

This clever machine slices the top part of the sticks where the fabric will go so you are left with just the inner section. The fabric needs to pass and fold to the left and right of this section.

The making of a Khu Khu hand-fan Stage 6
The making of a Khu Khu hand-fan Stage 6

Step Seven - Mounting the Fabric Onto the Sticks

Possibly the most complicated part of fan-making is the mounting of the fabric. This part is done by a 'teledora' and must be done by hand. How the fabric is mounted depends on a lot of factors including the shape, size, style and number of sticks involved.

The making of a Khu Khu hand-fan Stage 7
The making of a Khu Khu hand-fan Stage 7

But one thing remains the same every time; the fabric is folded between two pieces of thick card, a kind of concertinaed mould, which gives the fabric the correct folds. This folded fabric (which keeps its shape due a pre-starching treatment) is then glued to the sticks and the excess trimmed away to leave a beautiful and neat little wonder.

The making of a Khu Khu hand-fan Stage 7
The making of a Khu Khu hand-fan Stage 7
The making of a Khu Khu hand-fan Stage 7
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