Deni's Gingerbread Dough (Oven Plywood)
adapted from: http://www.gingerbreadexchange.com/recipes/deni's-gingerbread-dough-(oven-plywood)/
Also known as oven-plywood - The recipe that follows makes excellent, stiff gingerbread dough. It is NOT your basic gingerbread dough. Please read the instructions thoroughly BEFORE starting - this is a very intense recipe. Once you start on the heat section - you can't stop.
NOTE: An electric mixer is NOT recommended. This dough is VERY stiff and could easily burn-up a mixer motor.
I have found this is easier to do in half batches. Makes it easier to get stencils and molds cut out and keep dough warm. Plus the amount is easier to manage in the kneading phase.
Equipment needed for full batch (4 cookie sheets): 13 Qt. stainless steel mixing bowl (must be stainless steel - it will need to be placed on direct heat - I use a large pot), 9 qt mixing bowl, smaller bowl, measuring cups and spoons, whip, large spatula.
STEP ONE: Prep cookie sheets and have knifes, stencils, and texture mats ready
STEP TWO:
7 cups All Purpose Flour (1/2 = 3.5 cups)
7 cups Rye Flour (1/2 = 3.5 cups)
*her recipe calls for 6 cups each - but that is never enough
Measure All Purpose Flour and Rye Flour into the 9 qt. bowl. Sift flours together to blend, set aside.
*I usually make all the flour mixture all at once and then set aside 1/2 for round 2 - easier to sift all at the same time
STEP THREE:
2 tsp. ground Ginger (1/2 = 1 tsp)
2 tsp. ground Cinnamon (1/2 = 1 tsp)
2 tsp. ground Cloves (1/2 = 1 tsp)
1/2 tsp. ground Nutmeg (1/2 = 1/4 tsp)
1 tsp. Salt (1/2 = 1/2 tsp)
Remove about 1 cup of the blended flours and place in small bowl. Measure Ginger, Cinnamon, Cloves, Nutmeg and Salt into the small bowl. Blend this small amount of flour and spices together, then add to large bowl of flour. Sift (or stir well) to blend.
STEP FOUR:
2/3 cups Lemon Juice (1/2 c)
2 beaten Eggs (1)
2 beaten Egg Yolks (1)
Combine Lemon Juice, Beaten Eggs and Egg Yolks in another bowl. Set aside, near stove.
STEP FIVE:
1/2 cups Margarine (1/4)
1 1/3 cups Honey (1/2 + half of 1/3)
3 1/3 cups Sugar (1.5 cups + half of 1/3)
Combine Margarine, Honey and Sugar (in that order) in the 13 Qt. mixing bowl or pot. Place over medium heat - do not leave unattended. Stir with large spoon while heating until Margarine and honey are melted and sugar can easily be stirred into them. (Sugar does not need to dissolve, just blend). Remove from heat.
STEP SIX:
Combining:
While Margarine/Honey/Sugar mixture is sill warm, add Lemon Juice/Egg mixture. Stir with a wire whip until well blended.
Begin adding Flour/Spices mixture to the Honey Mixture. As the dough gets stiff quickly, change to a large sturdy spoon. Stir in as much of the flour as you can, then begin kneading the remaining flour. Dough will be sticky at first, then becomes very stiff as you continue adding the flours (I start with 6 cups of flour mixture and usually end up using 6.5 by the time I am done kneading).
Very useful: I put the 13 qt. bowl in the kitchen sink, and knead the dough directly in the bowl. It is much easier on the arms and a lot less mess.
STEP SEVEN:
Knead the dough until it makes a smooth ball. Keep it covered with plastic wrap. I divide it in half to finish the kneading and to cover with plastic (one for each cookie tray).
Use the rest of the flour mixture (variable amount) to be used to "dust" your rolling pin and surface.
I roll each ball out on the foil that is pre-measured. Then I fit the stencils to the pan. I preheat the oven to 350 when I start the first pan of stenciling.
Break off amount of dough to be used for house piece to be cut. Knead again to make smooth. The dough is very difficult to roll if it becomes cool/cold. You can keep the covered dough in the stainless steel bowl on top of stove while oven is on OR if the dough cools down, pull off a piece you intend to roll, wrap it in plastic wrap and microwave 15 - 30 seconds at a time. This re-heats the honey slightly and makes it easy to handle. (I use the microwave method - works great). Dust surface and rolling pin, roll to desired thickness.
Cut pieces and bake at 350 degrees for 15 min for 1/4" thick, 20 - 25 min for 3/8" thick. Check pieces - different sizes may need different settings.
All pieces may be returned to the oven to bake more if necessary (if they didn't get brown or hard enough).
Tips for Rolling, Cutting and Baking
THICKNESS: You can use a gauged rolling pin, that is, one that has interchangeable rings so your dough is the proper thickness - this is helpful if you have 2 different pans of the same building support pieces.
Larger structure/support pieces should be rolled 3/8". Pieces that are not support can be rolled 1/4" or thinner.
Dough rolled paper-thin must be watched closely while in the oven - maybe 5 min. Thin dough can be used for shingles. Use a small cutter. Then use a knife to score each in half (not all the way through). This allows you to snap them apart when cool.
MOLD: By the time you get the dough rolled the size you need, it is cool enough to actually pick the whole sheet up and drape and shape over a mold if desired. Pieces that are draped over a mold may need to be set at 200 for about 45 min - 1 hr. They MUST be completely baked or they will cave-in. The low temp will dry, but not brown the surface further.
ROLLING ON FOIL: Lightly wipe the counter with water then spread a sheet of aluminum foil down (the water keeps the foil from moving, but can also cause your gingerbread to bubble up a bit while cooking). Roll dough directly on foil. You can either cut pieces now or lift foil and place on baking sheet, then cut your pieces (prevents misshapen pieces).
CUTTING: For the straightest and cleanest edges, especially windows and doors, leave your scrap dough in place after cutting. Trim it, but leave 1/2" or so strip all the way around the piece. This prevents the edges from baking darker or spreading. (I tried this and it works great, but you really have to be quick when pieces come out of the oven and run a knife or pizza cutter across cuts again to make sure they separate well).
When the piece is baked and is still hot to very warm, you can pull those pieces away from the edges and out of the windows and doors. You can also press or repress additional patterns into place. ie - hatching
DRY IT OUT: At this point I leave the pieces for a half hour or so and then I separate them and move them to cooling racks for a day or 2.
Anytime BEFORE you apply any royal icing, if you feel a piece is not completely dry or you see that it is slowly bending out of shape at room temperature, PUT IT BACK IN THE OVEN at 250 - 300 degrees. Pieces that are draped over a mold may need to be set at 200 for about 45 min - 1 hr. They MUST be completely baked or they will cave-in. The low temp will dry, but not brown the surface further.
CANDY WINDOWS: To make melted candy windows, allow the piece to cool completely. Brush crumbs from all cut edges, square the corners. Lay on sheet pan on top of a piece of foil. Spread cracked/crushed candies in window hole, brush any candy flakes off surface around window. Place back in the oven and heat only until candies melt and fill corners (Push it into the corners with a toothpick if necessary). If bubbles occur, use a straight pinto pop while the candies are still liquid. These windows won't fall out. If you use different colors in a window, you can swirl them while it's hot. Use: jolly ranchers, hard suckers, etc.
Notes
This gingerbread is NOT conventional. Most recipes instruct you to refrigerate the dough. DO NOT REFRIGERATE THIS DOUGH. It is tough and dense so must be warm to knead and roll. Your hands and arms will be better off. It will cool quickly enough to make clean cuts and be able to manipulate. This is the result of using Honey instead of Molasses, and the additional 50% Rye Flour.
