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The sheer difficulty of making the Tefillin made me think about how it was done in the past but of course Tefillin didn't always look like these - originally they were leather pouches with k'laf in them and then subsequently reached the form we know. It is only the use of industrial presses and precision drilling tools and the quest for ever more perfect 'squareness' that has made it harder for the human to interface with them. My own small simple ones don't look anywhere near as complex. So a future project for me is to make some P'shutot M'hudarot (nice simple ones) batim myself when I feel up for the complex origami it involves and have some spare time (so probably never then).
Having sewn, the next stage is to repaint the bases so that you cover up the whiteness of the giddin thread and paint over the join. To get a nice finish this involved a number of coats, sanding after each one.
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