1. 1. Making the Iron BaseAn iron plate is cut and filed to the shape of the workpiece.

2. 2. Polishing the Iron BaseThe iron surface is polished by filing to remove surface rust, dirt, and stains.

3. 3. Fixing the Iron BaseThe iron base is fixed into a work stand made of pine resin and stone powder. The
iron base surface is filed or polished with sandpaper to smooth.

4. 4. Drawing the DesignAfter deciding the inlay patterns and layout, a design is either directly drawn on the
base with a brush, or onto a sheet of thin paper, which is transferred to the base by using a graver. The
artisans are free to display their creativity in this important process.

5. 5. Nunome EngravingUsing a hammer and graver, the base is engraved with fine lines in four directions:
vertical, horizontal, and diagonals. The lines are so fine, about 16 fit into a 1 millimeter square; in addition
vertical lines are cut deep, and horizontal ones are shallower.

6. 6. Cutting out MotifsA typical inlay flower design will be made up of leaves, petals, etc., and these individual
shapes are cut from gold, silver, or electrum (gold and silver alloy) sheets. A roller is used to ensure a uniform
sheet thickness, which is about four times that of Kyo Zogan (Kyoto-style inlay). This extra thickness gives a
deeper impression characteristic of Higo Zogan. Motifs are cut out from the metal sheet, placed on a dish,
and heated to soften and increase the degree of adhesion with the iron base; this process is known as
namashi.

7. 7. HammeringFor example, several heated gold metal petals are placed on a nunome section of the iron
base; each one in turn is gently pressed down with a rod made from deer horn, and lightly tapped with a
hammer until the distinctive crisscross nunome pattern is seen through the gold of the petal.

8. 8. Hammering to TightenAny excess gold metal of the petals is trimmed according to the design, and the
metal surfaces are beaten by using a special hammer until they are smooth. In this process the nunome
patterns on the petals disappear, and the iron base and the gold of the petals will be closely bonded.

9. 9. PolishingThe surface is rubbed to polish, and further beaten with the deer horn rod and a hammer to
tighten.

10. 10. Erasing the NunomeA pencil-shaped iron rod is used to scrape away all traces of the nunome from the
iron base, after which the surface is made smoother with a kisaki tool.

11. 11. PolishingSeveral types of polishing rods are used to return the iron base surface to its original smooth
condition.

12. 12. Hairline EngravingThe detailed parts of the inlay design are completed using a hairline engraver, after
which the surface is polished with an abrasive to finish the inlay work.

13. 13. Rust PreparationThe polished iron base is removed from the work stand and any attached resin and dirt
removed. It is then placed in a nitric acid solution diluted with water until the surface tarnishes slightly; then
ammonia is added to neutralize the solution. The iron base is removed and held under running water. This
process creates a rough base surface, allowing rust to evenly develop.

14. 14. RustingLiquid to encourage rust is applied all over the iron base surface, which is then heated over a
flame to develop rust. After heating, the base is cooled and dried. The rust liquid is again applied and the
same process is repeated. Depending on the temperature and humidity, rust development varies; it is
important to evenly rust the whole surface.

15. 15. Preventing RustThe base is left one night, and then boiled in tea for 30 minutes. The tannin in tea leaves
neutralizes iron oxidation, stops rust, and also changes the rust color to the deep black of Higo Zogan. The
base is then removed and cooled with water, and after draining, is held over a flame until white smoke is
produced, and the base is removed.
16. 16. HeatingCamellia oil mixed with lamp soot is painted on the base, which is again heated. By repeatedly
painting and heating, a coat is formed on the surface and further rusting prevented. Finally, the surface is
polished with camellia oil to beautifully bring out the gold and silver patterns. This is followed by shading or
engraving to finish.

17. 17. Assembly and CompletionAny metal fittings or accessories are attached and the Higo Zogan item is
now completed.