Our Process
Transforming old lobster rope into new home decor products is a labor-intensive multi-step process.
Source, Collecting, Sorting, Prepping, Weaving, Washing, Drying, and Finishing
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Source: We source all our rope directly from Maine lobstermen. We find them via Facebook marketplace and groups, will exploring fishing communities along the coast, and some contact us directly.
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Collecting: The rope is typically stored in coils, but not always! Using a pickup or trailer the sourced material must be hauled back to our home workshop where we store it outside and in our drying greenhouse.
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Sorting: After hauling the rope home, it is sorted by color, size and type in our backyard. This makes it easier for us to quickly find and plan for available designs. It also looks nicer than a random pile.
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Prepping: The rope coils are dried indoors and depending on their condition might require a pull through our wire brush scrubber. The coils must be unwound, and frayed ends and knots must be removed. We use a purpose-built rope cutter to quickly part out the rope. Next referencing a spreadsheet we maintain of our designs, we cut the necessary lengths of rope. This allows us to prepare the minimum lengths required to complete a product, thus reducing any scrap "short" material. Also, it means we don't have to pull extra material. We will typically prepare multiple of the same product in order to have more inventory. Sometime the supply of a particular rope only allows for a limited run, or one-off design.
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Weaving: We've developed our own jigs to weave upon. The mats use predetermined horizontal and vertical fixed layouts which corresponds to the number of passes and overall size. Rope ends are joined to themselves because they start and end to the same point. Our wreaths and celtic knots are woven on a rotating jig which can be adjusted for various sizes dependent upon rope lengths and diameter. They have their ends mechanically fastened and typically get a metal hanging ring. All products are woven prior to washing so it can get messy in the workshop. (Cleaning the shop is a constant chore)
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Washing: Cleaning the rope with a pressure washer is very difficult when coiled or loose, thus we weave first and wash second. Only high-pressure water is used to clean the rope. No chemicals or cleaning agents are used or required.
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Drying: All drying is done without heat. We hang products outside whenever the weather allows, and indoors during winter in our dry basement with a fan. Most of the water drains rapidly, and the dampness dries within 2-6 hours depending on the humidity.
- Finishing: The washed and dried rope products have one or more steps before we can sell them. Wreaths are glued to help them fold their shape even when handled or dropped. All products get our label and then get quickly run under a heat gun. The high heat melts any frayed bits and brings out some of the ropes original color, making dull tones pop a little more.