WHEELWRIGHT: BUGGY, WHEEL AND HARNESS REPAIR A BLAST FROM THE PAST

Many of the tools used at Gerald Thompson's shop are as old as the antique wagons.

Two-hundred years ago, getting around the country was harder -- slower.

There were no trains, no cars, no planes.

There were no railroad depots or rails, no garages, no airports.

In their place in small communities along overland routes were buggy-making shops, wheel repair shops and harness repair businesses.

Horse-and-wagon and horse-and-buggy was the family's mode of transportation.

Wheel making and wagon making were big business.

It's still big business in some locales. In Colonial Williamsburg, in Virginia, a full-time wheelwright is employed, supervising the upkeep of 30 vehicles used in that historic area.

In addition to making wheels, the wheelwright and his team of apprentices build and repair 18th-century replica cars and wagons.

In a number of Amish communities in the United States -- including the Midwestern states of Illinois, Indiana and Iowa -- horse and buggy transportation is still the mode of transportation, and harness and buggy repair shops are plentiful.

Aside from Williamsburg, Amish country and a few other historic sites, the use of wheelwrights is limited.

But there is a wheelwright and a buggy shop in Southeast Missouri.

Gerald Thompson and his wife, Mary, own Butch's Harness & Buggy Shop near Fruitland.

The new harness shop in a 4,400-square-foot building near Routes 177 and W provides sales, service and repair of old and new buggies and harnesses. Available is a variety of new tack and saddlery, saddle soaps and conditioners and new wagons.

Mary Thompson, who produces handmade baskets and re-canes old chairs, also uses part of the building to sell antiques and collectibles.

Thompson previously worked as a part-time wheelwright from his farm, while working at a handle factory.

"I built my first buggy when I as 17 years old," said Thompson. "That was more than 25 years ago."

"I have always had horses, and early on, I wanted a buggy," he said.

Thompson started visiting antique shops. He found a spring buggy.

"It needed a lot of work, including new wheels," said Thompson. "I also had to repair and make some harnesses for it."

Since then, Thompson has been in the harness and buggy business.

"We make harnesses out of leather and bio-plastic," said Thompson. "We don't make saddles, but we repair them."

Thompson is restoring two buggies -- a pony buggy and a spring wagon.

"The pony buggy is unique," said Thompson. "It is about half as big as a regular buggy and was used years ago by children for transportation to and from school. A small pony was used to pull the buggy.

Thompson is making a new box for the spring wagon.

Thompson said he could purchase wheels for buggies, but many people wanted homemade wheels.

"And it's a great feeling to know that you have made something yourself," he said.

Thompson spends a lot of time explaining his trade to visitors. The job, he said, requires an interest in history and a desire to build something.

"It's interesting and rewarding, but different," said Thompson. "But the woodworking, research and construction are satisfying."

For instance, did you ever notice that wagon wheel spokes are oval shaped, not perfectly round?

There's a reason for this.

"Spokes are the touchiest part of the job in making a wheel," said Thompson. "They have to be `dished' just right, or they can wear out in a hurry."

Thompson is patient as he explains the whys and hows of spokes.

The oval shape gives spokes a "tremendous amount of additional strength," said Thompson.

The "dish" is important, he added.

The dish curves toward the inside of the wagon, so that, as more and more weight is added, the hubs are forced outward and the spokes straighten up rather than bow out.

"This is important for weight or when the wagon is riding on sloped ground," said Thompson. "If the wheels weren't dished, then, as the load shifted toward the downside of the wagon, the wheels would bow outward and probably split apart."

At one time, spokes were carved with a drawing knife from blocks of wood.

Spokes now are turned on a pattern lathe. Once the hub is created, the spokes are driven into the mortises of the hub.

"No nails or glue are needed," said Thompson. "The slope of the mortises in the hub creates the required dish."

All-in-all, it's a pretty intricate task, and about as difficult to explain as it is to make.

Once the spokes and hubs are intact, a pattern is made for the wood rim of the wheel.

"These rim portions -- usually six of them -- are called felloes," said Thompson. Traditionally, they are cut out with a felloe saw, from 1 1/2-inch oak stock.

Once the felloes are prepared, holes are drilled to fit the spokes. The felloes are laid, section-by-section, on the ends of the spokes, and mounted into place.

Once the wheel has been completed, it is ready for a metal rim (or, tire)

The tire (iron rim) should be made a half-inch smaller than the outside circumference of the wheel to insure a tight fit.

Not to worry if the rim is a bit big. A section can be cut out, re-welded and placed back on the wheel for fit. The rim is then removed, heated and replaced on the wheel and pounded evenly all the way around,

"I don't have to make many wheels from start to finish," said Thompson. "Most of the wheels brought here may need a spoke or two or a rim."

Still, there have been times, said Thompson, when "I have to match a wheel."

Thompson has been building wheels and buggies and repairing saddles and gear a number of years.

"We opened our new facility here this year," he said. "We spent the winter building it."

Thompson said he could purchase wheels for buggies, but many people want homemade wheels.

"I enjoy making wheels," said Thompson. "It's more fun than buying a kit and assemble a wheel."