Monday, March 30, 2015

New Brush Project #4 Finished


The project was started on March 17, and the first brush handle was completed and fitted with its knot on March 30. I put together this montage of pictures showing the process from tree limb to finished shaving brush. 


1. The blank is cut out of the limb segment in an octagon shape.
2. The corners of the octagon are rounded off to make a cylinder.
3. Four grooves are routed in the blank, and one end is tapered.
4. The blank is divided into two sections with the router.
5. The two halves are separated with the band saw.
6. The first of the two halves takes shape and the hole is made the size of a nickel.
7. After smoothing and sanding, the first coat of polyurethane is applied and hung to dry.
8. The hole is made 15 mm deep and a second coat of polyurethane is applied.
9. The knot is ordered from Whipped Dog.
10. The High Mountain Badger knot arrives from Whipped Dog.
11. A little Dremil action and the dry fitting is complete.
12 - 13. After the dry fitting, the knot is epoxied in and set aside to cure.
14. Post bloom. 
15. First shave.

To continue this story click on Jayaruh #4 Post Bloom

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