THINGS TO KNOW WHEN DIRECT WARPING

 There are some things that should be more clearly stated about direct warping that go beyond the back process and often are left out all together.  One of the first things to understand is that when direct warping - whether you are using a single vertical peg, or a horizontal rod as I have described in the article on this site, "Another Way to Direct Warp", multiple pegs, or hybrid warping using a warping board to direct warp - is that all you are doing when you bring the yarn from the loom to the warping peg (etc.) is measuring the yarn to weave the length you want your weave to be on the loom.  That length of warp on the loom is not the length of warp you want your final off the loom length to be. It is longer to account for shrinkage, waste, fringe, tie on, etc. This length is calculated as part of your project calculations with a weaving calculator.  To get that length that the calculator gives you for your warp you need to measure the distance from the warping peg to the position of the apron rod in the back of your loom at which you will warp to.  With a single peg - measure from the center of your loom - to the peg. 

When you warp to a single peg your warp is creating a V shape with the point of the V at the peg and the top of the V at each end of the warp on your heddle. Geometry tells us that the distance from the point of the V to the center point between the two legs of the V at the top of the V is shorter than the the length of each arm of the V. (This can be confusing at first - so take a moment to read that last sentence again and let it sink in.) What does this mean? It means that the warp at the center of the loom is shorter than the warp at the ends - and this distance right and left of the center of your heddle gets longer. You want all of the warp yarn to be AT LEAST the length of the  center of the heddle to the peg. This means you will have longer warp on the sides - but that is necessary when warping with a single peg - or your warp will be too short for your project.  Are you wasting some yarn? Yes. Is there a way around that? Not if you warp to a single peg. With a horizontal rod to warp to you should have equal lengths of warp from heddle to rod. With a warping board for hybrid warp, you will still have the V. With multiple pegs, you will have less of a V though you will create multiple Vs warping to multiple pegs and yarn length will still vary but not as much.. 

 When new weavers direct warp - and some experienced weavers as well who have not figured out this next thing - they often find the warp peg come flying off the table it is attached to and the peg and the yarn come at them at the loom resulting in warp tangled on the floor. Sometimes the warp can be salvaged and sometimes it can't. This happens to many - it happened to me on my second project ever and it happened twice during that warp. The first time I could salvage the yarn. The second time I could not.  Why does this happen? There is too much tension on the warp between the loom and the peg. 

There is no need to have tension on the warp when you are warping to the peg! As we just established above you are measuring the yarn when you warp to the peg. If there is tension on the warp, the warp acts like a spring - if you pull a spring too much it wants to spring back! The peg will only take so much before the warp wants to pull it in the direction from which it is being pulled - and it is going to go flying.  To prevent this there are two things you can do - one is to clamp the peg on the far side of the table and never the side closest to the loom. Closest to the loom if the peg is pulled it has nowhere to go but at you. On the other side of the table when it is pulled it will first pull itself into the edge of the table it is clamped to. But sometimes even that will not stop it and it still comes flying off with the warp. Or the pulling causes the warp to travel up the peg and come off the top.

One other thing that happens when there is too much tension on the warp from the loom to the peg is that you are stretching the yarn. Again, think of the yarn as a spring. As it is pulled it gets longer - much longer than the spring is when it is not being stretched from pulling. And since you are measuring the yarn to the peg, what is happening with the yarn under tension is that when you take the warp off the peg to wind it on the back beam as soon as it is off the top of the peg, the warp yarn RELAXES! And it gets SHORTER! Oops! What you thought was 90" long was stretched to 90" long and it really is 85 inches long or shorter! Your warp is too short for the length of the project you intended to weave, and you won't know it until you get near the end of your warp on the loom while weaving and you are no where near the length you thought you would have.

There is no reason for the tension. It is OK for your warp to sag from the loom to the peg AS LONG AS it sags consistently from one end of the heddle to the other.  This is not a problem. It may be a little longer than you need BUT LONGER IS BETTER THAN SHORTER when it comes to warp! 

But the books say to wind the warp onto the back beam under tension! Yes, it does but you have not been winding on yet - you are just measuring your yarn from the loom to the peg while you warp. When you have warped all of the slots and take the warp off the peg to wind it onto the back beam THAT IS WHEN YOU PUT THE WARP UNDER TENSION. 

When you are more experienced these things start to click and make sense. It really is simple but you don't usually see this in a book or even in the videos showing direct warp to a rigid heddle loom. 

What else can go wrong?  Lets go back a little - before you have warped the loom but are about to start. Look at your loom. The heddle is generally located not at the center of the loom but more toward the back of the loom frame. The space from the heddle to the back of the loom is shorter than the heddle to the front of the loom. SHORT END IS THE BACK OF THE LOOM. LONG END IS THE FRONT OF THE LOOM. THE BACK OF THE LOOM IS THE WARP END. THE FRONT OF THE LOOM IS THE WEAVING AND FINISHED CLOTH END. Before you warp make sure your loom is facing the correct way. AND when direct warping you put the FRONT of the loom toward the warp peg. You bring the warp from the ball of yarn around the back APRON ROD (the apron rod is the dowel or flat "stick" that you attach the warp to) through the slot in the heddle and over to the direct peg - put ir over the peg and come back to do this again for the width of your warp in the heddle.  So now you know what is the back of the loom and what is the front of the loom. You do not want to weave from the back of the loom - the space between the heddle and the beam is just too short.  Weaving is done on the front of the loom - the long part of the loom.  

ALWAYS WARP SO THAT THE YARN IS CENTERED ON THE HEDDLE. (When you get a new heddle the first thing you should do is take a marking pen and make a mark on the heddle frame at the center of the heddle - either that will correspond to a slot or a hole.)  Do not warp with the yarn on one side of the heddle and the rest of the heddle is empty. As you weave you are weaving with the warp under strong tension between the beams. If you are not centered you are pulling he beams on the side the warp is on and the empty side is going to try to flex - which can break the beam. When planning out where your warp will go on the heddle - with the heddle off the loom and in front of you on a table, start at the middle slot and count out to the right and then to the left to find the starting warp slot and the ending warp slot with the center slot in the middle. This means when you count to one side, count the center slot BUT when you count then to the other side do not count the center slot it is already counted - start in that direction with the slot next to the center slot. A simple tip is to take a piece of yarn and tie it around the top of the frame of the loom through the starting slot and another through the ending slot. On the loom when warping start at one marked slot and stop at the other marked slot. If you often use the same widths to weave on that heddle - keep the marking yarns tied on  - use a different color pair of yarns for different weaving widths and make a note of which is which width. (Sounds like it is part of a song in the Wizard of Oz! 😀 )  And before I start singing - we will move on. 😉

Also before you start weaving, you may notice that the heddle (on some looms) is different on one side from the other side. On some rigid heddle looms the heddle is bumped out on one side. On other rigid heddle looms the heddle is flat on both sides. So which is the front of the heddle and which is the back?  With a heddle that is flat on both sides it does not matter. But guess what? On a heddle with the bump out on one side and flat on the other it also does not matter.  Kromski looms and Ashford looms have heddles made with the bump out on one side of the plastic of the heddle - it is in the area of the hole. One thing that this does is strengthen the plastic around the hole. Yarn passing through the hole constantly is not going to wear through that thicker plastic that forms the bump. But is there a front and back and a right side and a wrong side to use to beat with? Not really. Some will say the name of the company that made the heddle is on the front of the heddle. Hmm? Kromski puts the name on the heddle on the same side as the bump out. Ashford puts the name of the heddle on the flat side of the heddle. Which one is right? It is really a matter of personal preference. My own preference is to beat with the heddle with the bump out. I find that it pushes the weft row more directly than the flat side BUT am I right? Some like using the flat side.  Are they wrong? Some looms only have a heddle that is flat on both sides. Is that a problem? NO! There are as many using the bumped out side to beat with as there are those using the flat side when their heddles have two different sides. (An interesting side note - Kromski's 10 dent heddle is flat on both sides. When I asked them about this they had no answer as to why the 10 dent is flat and the 5, 8, and 12 dent heddles are bumped out on one side.) So decide for yourself if you have a bumped out heddle on one side. Try a project one way and another project the other way - and see which you prefer or conclude that there is no preference. 

OK - here is something that comes up in discussions often. You will see in books and in videos on direct warping that it is said that when you put the yarn around the apron rod to put it in the slot you MUST alternate the yarn going over and under the apron rod - first over, then under. When I first started weaving I was making myself crazy making sure that I got this right - checking with each warp slot that I passed the loop of yarn through. GUESS WHAT? The yarn goes this way whether you think about it or not. It can only go this way - over and under alternating - it does it itself. If it is not, you did something wrong in bringing the yarn from the ball to go around the apron rod and through the slot. It really cannot go any other way if you are warping correctly. 

 When you wind the warp onto the back beam, you are winding the apron rod on with the warp tied on  to it and with the warp UNDER TENSION (how you put the tension on is another article in itself), you must put a warp separator under every layer of warp that you wind on. Warp separator can be as simple as sheets of brown package wrapping paper. A warp separator must be thick and it must not compress so that the one layer of warp sinks into the war layer below. Thin paper - even thin cloth  is not a good warp separator as it will push in with each warp under tension and push into the row below and maybe even rip the paper. The purpose of the separator is to keep each layer of warp apart and not mixing into the layer below.  Some use flat strips of wood put in between the warp as it is wound on. Some use the rubber no slip shelf liner - the one with the bumps on the surface of rubber. Many use the package wrapping paper which is sold in office stores or even Walmart in the stationary aisle. That paper lasts for a long time and many weaves.

There is such a thing as double warp. I am not going to go into how that is done but know that it is two warp threads in each slot and each hole. The yarn that this is done with MUST be thin enough to fit doubled in a slot and in a hole. Don't force it in - it will just rub and break as you are weaving. A beginning weaver should not be doing double warp until they have a lot of experience with single regular warp.

What can go wrong while warping? 

 If you find that there is not enough warp yarn on the ball after you have been warping and then passing  the loop through the slot in the heddle does not make it to the peg, stop and bring that loop back to the loom. Pass it back through to the back of the heddle and tie it onto the apron rod. Get another ball of warp yarn and tie the end on the apron rod and keep warping, Make sure you are starting in the now empty slot that you found the warp was too short to make it to the peg. It is always good to have another ball of yarn on hand - for warp and for weft.

Before you take your warp off the warping peg, go across every slot and make sure you have not missed any slots that needed a warp loop going to the peg. It is far easier now to fix this than later.

When tying on the warp to the warp apron rod - at the start of your warp or at the end - or in between - make sure your knots are strong and cannot come loose. A loose knot here will cause problems when you get toward the end of the weave. Double - even triple knots are good! 

When you have tied your warp to the front beam, every bundle of warp that is tied on must be equal in tension to all of the others. Go along the bundles and the warp behind the heddle with two fingers and tap gently. Every bundle must feel the same tension. If not you will have problems when you weave. It can take multiple adjustments back and forth across the warp bundles to get them even. Time spent here with this will save problems later.

 

Once you have finished warping go and read my article on weaving a header. That is the next thing you have to do before you start weaving with your project yarn! 

 

FIRST WEAVE A HEADER

After you have tied your warp onto the front cloth beam and are ready to weave, before you start weaving with your project yarn, you need to do something about those triangular bundles of tied on warp that is pulling your warp to follow those triangles. To fix this, before you start weaving with your project weft yarn you need to weave a header. The header will straighten all of the warp from your heddle to your apron rod with the bundles tied on. Weaving a header is simple.

You will need something that is NOT your project yarn to do this. Any scrap yarn can be used. It is best that it is thicker than your warp yarn. Some have even used rolled toilet paper to weave a header. The header is going to be removed when your weaving COMES OFF THE LOOM so you want to use something that is going to be easy to get out. I use something called Mason Twine. This is a polycord that is used in construction to lay out brickwork or pavement. It is inexpensive. It can be found at home stores like Home Depot or Lowes. Any hardware store should sell this. Walmart sells this in the aisle near hardware that has rope. You get a lot on a roll.  It looks like this on the spool -

This is cord is slick. It slides easily and when it is time to pull it out, it just slides right out.  When you cut this cord it is best to seal the end so that it does not unravel. Just put the end of the cord near a flame for two seconds and it will start to melt. That's it. 

To measure how ,much you will need unwind the cord from the roll over your warp. Go across your warp eight times plus an extra inch or so each time to have enough cord. You now have enough cord to weave your header.

You are going to start about two or three inches above where your knots are on the warp beam. Adjust the tension on your warp to weave - same as if you were about to start weaving with your project yarn. 

With the mason twine I find it does not stay on a stick shuttle very easily, so I use the stick shuttle to push the yarn through the open shed using the slot of the shuttle to hold the yarn as it goes through. 

1. Open the shed. Take an end (doesn't matter which) of the header yarn or mason twine and push the end through the open shed to the other side with the end of a shuttle. Grab hold of the end as it comes through and pull it through. You want almost the entire length to come through the open shed. Leave a tail with the opposite end hanging out from the side you started on. Straighten the cord or yarn across inside the shed. Close the shed to neutral. DO NOT BEAT.

2. You are now on the other side of the warp with the long cord. Do as you did in STEP 1 going back the other way. Open the shed, push the end through getting most of the yarn out the other side. This time DO NOT pull the cord/yarn that goes over your warp end  to the other side so that it tightens against the end warp thread. Instead leave a loop hanging out. DO NOT BEAT.

3. Repeat STEP 2 twice more but with the fourth row of this header yarn. Here is what this will look like at this point - 

4. NOW you are going to BEAT all four rows at the same time.  If the first row does not move, don't worry about it. Make sure the other three rows get up against each other and MAKE SURE YOU HAVE A STRAIGHT LINE OF CORD/YARN ACROSS THE WARP.  You see below what this looks like now - and you can see that the warp yarns above this start of the header are coming to straight with even spacing. But not completely - yet!

5. Now you should be on the same side you started on when you started your header. You are now going to start weaving with the header cord or yarn normally. 

I still leave a loop on the ends. I do not want the warp to be pulled in on the ends. I weave about four rows. Above you see the next row being put in - at an angle as you would do when you weave.

6. Keep weaving with your header cord/yarn until you see all of the warp nice and straight above the header to the heddle. I like to come back to the side I like to start to weave at. For me, I like to start on the right side of the warp with the heddle in the up position. If you start differently get your header yarn/cord to stop at the side you like to start weaving. If this means you have a lot of header cord/yarn left over, you can just leave it and it will wind up with the cloth or you can snip it off. Be very careful with scissors around your loom. You DON'T want to cut any warp threads. 

When you look above you see nice straight warp and even spacing. You are now ready to weave with your project yarn!

No matter what pattern you will be using for your weaving, start with a header first - no pattern - just plain weave.  If you don't weave a header you are going to find that your angled warp is going to make your beginning weave very uneven. 

When I start weaving after I weave my header, I move up a couple of inches from the header before I start weaving with my project weft. I do this to leave a space between the weft and the header so that when I hemstitch the end of the yarn on the loom (hemstitching article coming) the wrap will pull together in the hemstitch and allow for a nice tight stitch.

Some have other ways do create a header. Some use sticks that are woven into the warp. This can also work. For an rigid heddle loom, I have found that weaving a header as in this article is easy - and works every time.

A Dowel Replacement on A Kromski Loom

Over time the tension on the warp may bend your dowel rods on your Kromski loom. This is not a big problem to deal with. Dowels are available in every home store and in some craft stores. There is nothing special about the dowels Kromski uses on their looms. They are hardwood dowels. You can use a bent apron rod BUT it is best to keep the distance from the rod to the heddle at an equal distance across. When I noticed the bend on one of my Kromski apron rod dowels after using it a few months, I went out to buy dowels to replace the bent dowel. I bought a same sized dowel - you will need to cut it to length - even a small hand saw can do this - and I decided to buy an OAK dowel. Oak dowels are slightly more expensive but worth having a harder wood.

Home stores should sell perfectly straight dowels - as they should sell perfectly straight lumber but that does not always happen. Take some time to find the straightest dowel the store has. Take it to a flat surface in the store - heavy oak plywood is often flat - and roll the dowel on the flat surface and see that that it rolls flat and does not bump up at any point along its length. It pays to take time to get a good straight dowel.

I thought that this was going to be final solution, but wood is wood and in humid areas and with tension being put on the dowels on the loom, even the best round dowel will eventually warp or bend. I looked at the apron rods that Ashford uses - they are not dowels. They are flat strips of wood. If used with the flat side UP - meaning the edge of the flat wood strip faces the heddle and not the larger flat surface of the wood. I went out and bought a 1/4" thick board in one of the Home Stores. These thin boards are considered "hobby" boards or wood. I cut a strip off of that board as wide as the dowel on my Kromski and I attached it with the existing TexSolv apron cords that I had put on (see the last article). It is very hard to bend a strip of wood along its edge.

I only replaced on dowel with this flat apron rod. The cloth beam apron rod Oak dowel that I replaced the Kromski dowel with has been fine so far. If it ever needs replacement, I have more of the flat board to make a flat apron rod for this side.

It works! It will require someone with a table saw to cut the strip of wood to the correct width and then the length needs to be cut the same length as the Kromski dowel.

Different Apron Cords on a Kromski Loom

Kromski several years back changed the apron cords on their looms. At one time you received a long strand of nylon cord and the Kromski instructions told you to cut the cord into equal lengths and form looms with the cord which required holding the cord ends together in a candle and hoping to get them to melt - which meant needing to do this for all cords to come out to equal length loops which is not always easy. Then they decided to change how to use this long length of cord and put a screw at each end of the warp and cloth beams and tied the cord between the screws and showed in their new instructions how to wrap the cord around the apron rods to form "V"s to hold the apron rod loosely in place.

This works if you are using their "warp helper" block to warp your loom but did not work well when I tried to use this when direct warping. The problem on a 32" wide loom was emphasized when the dowel rod would dip down on one end while warping the other end and across. Some love this new setup and if it works for you don't change it. But I struggled with this for several months and then went out looking for an alternative.

I could have cut the cords into pieces and used the old instructions which are still easy to find on the internet to cut and burn the loops together and use them as they used to be uses. But I really did not like that. I looked to see what other looms do. One other company uses a plastic band to hold the rod to the beam. Another uses something called TexSolv - a product commonly used in multi-shaft weaving. The feature of TexSolv is that it is nylon cord made up of a chain of small loops that make it easy to put an end through one of those loops, pull and have the length of the cord on the loom exact as long as you you put the cord end through the same loop counting up.

I decided that the TexSolv was a great way to put the apron rods onto the beams and I went out to find it. If there is no weaving store near you, several of the weaving websites sell TexSolv. Some have better prices than others. Be aware that this cord is EXPENSIVE. You can buy it by the foot and you can buy it on a spool. I decided - not being sure how much I would need and not sure if at some point I would want to replace the TexSolv cords with new ones - to buy a spool.

Schacht has an excellent video on how to put TexSolv cord on the apron rods and beams of their Rigid Heddle looms and this process is the same for the Kromski. Here is a link to how it is done -

https://www.youtube.com/watch?v=DPGVyv3z8T8

Here is how it looks on my loom. Compare this photo to the one above. The apron rod is securely tied to the beam. You will see the two end cords not around the dowel - this is to keep tension off the ends of the dowel when weaving less than the full width of the loom. All I need to do is slip those back over the ends of the dowel.The best thing is that it is so easy to get equal lengths cord that enable your apron rod that you warp and tie onto the same distance from your heddle across the entire length of the apron rod.

Here are some close ups and you can easily see how this cord is constructed with small loops.

A small investment made using the apron rods so much easier. And you can easily slip cords off the dowels for narrow projects to put even tension on the dowels.