http://leisuretoursmalaysia.blogspot.my/2011/05/educational-tour-of-labu-sayong-cottage.html

 

STEP 1 – PREPARING THE CLAY SOIL

The clay found along streams and river banks at Sayong River is most suitable to make the Labu Sayong. Traditionally, this clay is left to dry under the sun for days. It is first pounded into extremely fine powder and then sieved from coarser remains and wood to obtain the finest and cleanest clay. Water is then added to this clay powder and kept in a container for a few days. During this process, the clay will settle down, The water is then removed and the remaining clay is taken out and put on a plaster slab to be kneaded and wedged. This process of kneading and wedging will remove air bubbles which can cause the pot to break when exposed to intense heat. After that, it is shaped into its distinct traditional ‘double-bulb’ shape. What a process…

Nowadays, the clay soil is mixed with Sodium and water in a simple improvised machine to produce a batter.

 

STEP 2 – MOULDING

The batter is pour into the mould. Let it set inside the mould for 3 hours or so depending on the weather. The bigger pot usually takes one day or so. The pot is removed from the mould and turn upside down to dry.

 

STEP 3 – SHAPING AND DESIGNING

The process of shaping and decorating is done on a simple rounded wooden board wheel rotated by hand.

 

STEP 4 – DRYING

The  pots are then dried in the sun for 3 days or so to harden the surface.

 

STEP 5 – BAKED

Back in the old days, the pots are fired in open trenches filled with dry rambutan trees, bamboo and palm fronds until they are red hot. They are immediately removed and placed on a pile of paddy husk or sawdust for 20 minutes to impart the black sheen. The base of the pot is brushed with liquid resin or wax to render it waterproof. Imagine all those opening burnings, sweats and hard work!!!

Nowadays, the pots are baked in a kiln at temperature of 1000 centigrade for 10 hours or so depending on the size and purpose. The longer the baking, the more expensive it is. However the original black Labu Sayong is still processed the traditional ways

 

STEP 6 – FINAL TOUCHES

Till this day, Labu Sayong is greatly admired, not only for its utility, but for its beauty and aesthetic quality. Beside the water pitcher, Labu Sayong can be made into lamp stands and vases. To produce the different, beautiful and unique looks, different techniques are used.