GAR-ZO: The art of blacksmithing; iron crafting art from lonely land Bhutan: A dying Art

Continuing “Zorigchusum”, Thirteen Chapter, thirteen crafts.

Here presenting information on: The Fourth Chapter”; “Gar-ZO”. The land is not lonely in terms of art and has amazing arts nurtured through years and to be gratified of.

Paksam: as depicted in Thangka paintings 

Introduction

8th century Gar-zo artifacts

The art of blacksmithing is the fourth art of “ZorigChusum”, which started in late 14^th century, by Tibetan saint DupthobThangtongyalpo, the esteemed master engineer for this skill in casting iron chains, and erecting them as bridges over gorges. In his credit are eight suspension bridges in Bhutan.  

A ancient example of gar zo art: An iron  chain bridge 

The bridges crossing over the Paro Chu, is one such bridge made by DupthobThangtongyalpo. It is on the road from Paro to Thimphu and is a highway. 

Remain of other bridges by DupthobThangtongyalpo are preserved at National Museum Bhutan.

Another Master piece  of Gar-zo Art: iron Chain Bridge

Blacksmithing is an old art in Bhutan and fighting for its existence of essence now. In Bhutan, now only, Tibetan settlers are practicing and preserving this art. Terton Pema Lingpa was another saint who had been inscribed to expertise Garzo.

8th century Gar-zo artifacts 

Village Barshong in eastern Bhutan took up the art professionally and had paid taxes to the government. The village had evidences of the smelting furnaces, holes dug up for smelting, and traces of wrought iron. Woochu in Paro, and Chakrola in Thimpu in western Bhutan are another such places.

A close look of Chain bridge 

About the process:ART of  Gar-zo The Blacksmith Art 

This may be considered as a primitive art which began in Iron Age, when man first started making tools out of Iron. Thus, it is considered as an art of converting crude metal found in rocks to usable trappings for longer uses. Spears, arrows, axes, knives, and swords were such usable articles. In small beehive shaped furnaces made of rock, an opening on the top and an entrance on the side, iron was smelted. These furnaces withstand regular heating and a temperature above 2,800^o F . 

An image to understand Furnace in cross sectional view 

These furnaces are filled with iron-ore and charcoal. It is then set on fire. At the high temperature of 2800^o F, iron melts and flows. It now hammered and converted to desired shape.

An ancient iron melting Furnace

Current scenario of gar-zo:

Garzo has withstood time mortalities and has now changed it forms, or it may had developed over the period of time, reaching current stage. The original art slowly disappeared and has been reshaped to Blacksmithing Industry. It may be broadly classified as:

1.      Armour-er: Blacksmiths who made Armour

2.      Blade smith: The knife, sword, chain, darts makers

3.      Lock smith: Lock makers

4.      Ferrier: Blacksmith who shod horses

Furnace process and making of Patag

 The legend of Garzo of Sword making: Patag is a type of single edged blade is now popular and traditional of BhutanGarzo art. It is highly specialized craft.

Patag, the ceremonials swords are made for gentry or senior officials for ceremonial honors. In Bhutan, all men wear ceremonial swords, on special occasions. Children wear a traditional short knife called the “DUDZOM”.

Bhutanese swords are named after the blacksmith who first kiln it, locality of origin, appearance, design and utility.

Image of various swords and Knifes: Gar-zo Art

It was made popular during the reign of kings

1. ‘Jigme Namgyal”. He was forefather of Wnagchuck Dynasty. He served as 48^thDruk Desi and held the hereditary post of 10^thpen lop (House) of Trongsa. He was also called black ruler.

2. Tongsa Penlop Ugyen Wangchuck. He was born on Phodrang Thinley Rapten. He was a farsighted statesman and strategist.

Sword used for wars were marked with cross placed on the blunt side of the sword.

Defiled swords are especially valued.

Different types of swords were cast in different localities of Bhutan.Bhutanese swords are straight, single edged, with sharp arc tip.

Making of Patag: “Garzo” Blacksmithing Art

1.      Iron ore is obtained from the region of Chakor la and Barshong.

2.      The process of melting the iron took from a week to a month, depending upon the size of furnace.

3.      The iron quality is related to the wood used for smelting.

4.      Smelting

Bhutanese sword at metropolitan Museum New York

Bhutanese sword and sccabard

The meaning of Chakor la is hill surrounded by iron ore. Traditionally, a dig of one story approx. is done to extract ore. The ore found is mixed with black soil. Digging is done using crowbars and pick axes. The crude ore is carried in baskets made of bamboo. Furnace is usually square in shape. A circular hole is dug inside the furnace to hold the ore. The furnace is fully filled with ore. Fire is lit. The process of melting the iron takes one week to one month. The duration completely depends on the size of the furnace. The melted iron is collected in various holes in the furnace. This is soft iron and called nyen cha. These are in the form of small iron balls. These iron balls are put inside charcoal and heated continuously to make it hard. Swords and other tools are then made out of it.

Sword and Knife fourth King Bhutan 

A good quality of iron is obtained by heating it with castanopsis(Chinkapin, evergreen tree of beech family), quercusglauca(ring cup oak tree) and rhododendron. 

A medium quality can be obtained by burning it with walnut, and Myrica woods.

A lower quality is received by burning it with Rhussimialataand RhusScandens woods.

Swords were then rubbed multiple times to remove stain with various materials.  Rubbing process involves various steps:

1. Rubbing on Shobda to remove stain and other marks.

2.To remove marks, stain in grooves and depressions, it is then rubbed with hide and water soaked sand.

3. To give ash black colour to sword, it is rubbed with dreyda.

4.To increase the gleam of the sword, it is rubbed with chagchey wrapped in hide.

5. To remove the dirt and patches of previous process, it is rubbed with soot and green leaves of artemesia.

6.The final process which involves removal of moisture, it is rubbed with powered charcoal of pinewood wrapped in a piece of cloth.

7. The final touch is given by rubbing it soft and dry cloth.

Scabbards

Gazo reaches its finesse with making of Bhutanese swords (Patag) which is further classified on the basis of descriptive designs of the Scabbards as:

1.      ChuriChemn: It has received its name due its wavy pattern. This wavy pattern is hence called CHURI. It was a matter of pride to chief attendant to king to carry churichemn. Churi is usually gold plated.

Churi Chenm

2.      Ben Chang: It is as equal to Churi Chemn except in design. It is plainer.

Ben Chang

3.      Belpachenm: It is only different from Churichemn in its design of scabbard. It is made of frog skin and silver cased. Frog skin is called Belpa, therefore, received its name Belpachenm.

4.      Hoshu Chenm: It is different from above three. The scabbard is painted with pelt, red and green. Visible are golden designs between the opening of scabbard and hilt. Rest par is plain and silver cased. It is matter of pride for senior professionals and elderly men of court.  Images.

Hoshu tenzin and Paksam tenzin

Other Bhutanese swords are:

1.      Paksam Tenzin

2.      Chukhap Tenzin

3.      BumthangTsen-dri

4.      Nagphala

5.      DungsumThum

6.      Barshongpa

7.      Thum

8.      Lungdri

Scabbard’s main body is made of Bashing and Dungshing wood. Making of scabbard starts with cutting of wood planks of two equal sizes. The wood should not be having any cracks. It is carved curve inside and pasted together with wood pasting glue and left to dry for few hours.

The wood is covered with silver case and then painted in different colours of pelt, which is usually wild animals, frog and cow, and further gold plated. Colours are black, green and red. Dyes are mixed with milk extracted from Seyshing and glue made out of cow’s hide. It is dried and applied to the scabbard and stitched tightly. Some of scabbards have wave like designs or knitted patterns, wherein gold in filled in the grooves and each intervals. Scabbard is 1.5 cm longer than sword. Now, India is major supplier for scabbard, reducing the process.

Hilt with silver knitted thread

Details Scabbard

Descriptions:Paksam Tenzin&HoshuChemn- It is a sword of nobles and kings, smooth, mirror like shiny sword and edges are blunt and round with three  grooves running the length. Sword is 160 mm long and thin at tip than hilt. Width rages from 40 mm to 33 mm, with edge thickness of 5mm at hilt and 2mm at tip. The blade and the blunt edge are made of hard and soft iron, which make it resistant to high temperature, humidity and corrosion, making it easy to bend meeting both ends without breaking. The sword derives its name by the village “Paksam” and “blacksmith “Tenzin” and so the name.

Blade of Paksam tenzin 

Hoshu tenzin and Paksam tenzin

Grooves in Paksam tenzin

Chukhap Tenzin & Buepa Chen: Its origin, name, shape and size similarise   with Paksam tenzin. It differs only texture of surface, which is not as smooth as in paksam tenzin. Both can be identified with each other with its sharp arc tip and the edge which look like tail of an ox and attractive washo. There are different contradictory stories for the origin of the name of these swords. As per few stories, neither paksam nor chukhap were casted in pasakha and chukha. However, paksam is the name of blacksmith and tenzin was supervisor.

Chukhap Tenzin & Buepa Chen

Nagphala: Also called Des i Nagphalam. Name has again various accounts in the pocket. It was crafted during the reign of desi Jigme Namgyal, so receved the name. Other accounts depicts its association with bumtang, a place in Bhutan, where the ruins of his forgery and unused irons can still be seen and this work of “Bumthang tsendri nagpo phala is the result of its casting from iron uncovered from this place and the thumb impression is seen on the hilt. As per one more narrations, it is believed that blacksmith was black, and so the name phalam, therefore called nagphala. The blade oscillates when bent and released, giving the impression of its lightness and shines, and so considered the best. The width of this sword is greater than paksam tenzin.

Dungsum Thum and Barshongpa: There is a lake Dungtsho Karma Thang in Bhutan. Hence, the traces of forging can be seen at the shore of lake. The credit of discovering this goes to Terton Pema.  Dungsum is the place famous for iron extraction. It is hard and shorter and the symbol of heros. The thickness remains same throughout. At eastern Bhutan, the other source of obtaining iron ore is Barshong.This place is also famous for casting many iron equipment. From this was traded various agricultural and domestic tools to many places. The forging is done using charcoal of Sisi and Gum which toughens the sword casted. As one of the folklore, iron from this place was also used to make iron chains used in bridges.

Dungsum Thum

Thum and Lungdri: This is not strong as paksam and it is without chu. It is not casted out of soft and hard iron and breaks easily if hit on hard object. Whereas, lungdri is soft and thin and easily cuts objects finely.

Courtesy: Bhutan National  Museum, Metropolitan museum NewYork, Journal of Bhutan Studies