The Manufacturing Process

1. Manufacture of the cuckoo clock begins in the hands of the wood worker. The craftsman selects the pieces of wood to be used for the particular clock and cuts them to the approximate lengths and shapes he will need. Power tools and hand tools are used for this part of the process; hand tools may include measuring tools, saws, rasps, and files for shaping, drilling tools, abrasives including sandpaper, and adhesives and clamps. The box-like case or cabinet for the clock works is cut, fitted, and glued together.

   The outer frame—the decorative part of the clock featuring the traditional forest and chalet scene—begins with a stenciled design on paper. The craftsmen make and collect sets of stencils based on their own drawings and those that have been handed down. The sets of stencils are made for specific sizes of clocks. After choosing the stencil for the size and style of clock, the wood worker draws the design on the wood and begins carving and shaping the frame. When the frame and the case are complete, both are stained and left to dry.

2. When the frame and case are dried, the clock is assembled by first mounting the movement in the case. In the old days of village manufacture, the craftsmen who carved the wood and assembled the clockworks probably lived in the same village. The clockmaker poured and handcrafted the internal workings of the clock himself and assembled them. Today, manufacturers buy preassembled clock movements, and the process is reduced to fitting it in the case and properly fixing it in place with wood screws or other fasteners.
3. The sound-making devices are attached to the top of the clock. These include the pipes and bellows for the cuckoo sound and the music box. Attachments that are usually extensions of drive chains are linked to the sets of wire hooks and metal cams and pins that activate the cuckoo and any other moving figures and the doors. The cuckoo is connected to its bellows operation, and the other figures are mobilized by the strike movement. A third movement initiates the playing of the music box. Finally, the pendulum and weight chains are connected to the movement and the lead weights are clipped to the chain ends.
4. The assembled clock is carefully packaged to protect the moving parts and the delicate carved framework. Individually boxed clocks are packed in cartons for shipping and distribution.
5. I will look at the video and revise notes.