Tag Archives: fitting a stem

Link

One of the pipes that I had been given years ago was stamped SmokeMaster Series 200 and was an acorn shaped rusticated bow with a smooth side on each side of the shank for stamping and a smooth rim. The left side bore the name and series number and the right side was stamped Imported Briar. The stem had been well chewed and the internal apparatus was missing. It was not useable on this pipe. I would have to restem it. I knew nothing of the brand name. My search on the internet gave me some information on the brand.

On the Dr. Grabow site ( http://drgrabows.myfreeforum.org/sutra13181.php ) I found some interesting information. I quote this post by Dave Whitney, the author of Old Briar, a book on refurbishing. “Smokemaster was a Briarcraft pipe. Richard Kliethermes Sr. was the founder of Briarcraft. First located on Pipetown Hill Rd, Spring Valley, NY, it moved later to 66 Central Ave., Spring Valley, NY. After the death of RK Sr., the business was run by Richard Kliethermes Jr. († 1943) and was quite prosperous between 1920 and 1940. The company closed in 1950. Briarcraft seconds are as follows: Airo, Arcadian, Briarmeer, Smokemaster, Cavalcade, Hallmark, Sterling Hall, and Wimbledon. The Orange off-center diamond was one of their logos.”

The link also had the following scan that shows the original design for the stems and the unique folded pipe cleaner filtration system of the original pipe. I decided to restem the pipe with a stem of my own choice rather than hunt down an original stem.

Please forgive the poor focus on the next three photos but they still give the idea of what the pipe looked like when it arrived to my work table. It was in rough shape. The bowl finish was spotty and the varnish was coming off. The rim was out of round and the back edge of the inner rim and top were beat up and rough. The stem was gnawed off and the short length would not work with this old pipe. The cake was thick and uneven with large flakes of tobacco stuck to the inner walls of the bowl.

I went through my stash of stems and found an old saddle stem with a built in brass band that would approximate the aluminum one on the original stem. I would need to do some work on the tenon length and the diameter of the saddle portion of the stem to get a correct fit but it was workable as the new stem.

I reamed the bowl with a PipNet reamer (Photo 1 below) and a plumber’s wire brush (Photo 2 below) to clean out the debris. I used a sharp knife (Photo 3 below) to reshape the inner edge of the bowl and bring it back to round. Photo 4 shows the reshaped and cleaned bowl. I would have to top the bowl to repair the roughness to the top of the rim.

I used a sanding drum on a Dremel to shape the saddle diameter to meet that of the shank. The sanding drum worked well on the vulcanite and the brass. Due to the difference in hardness of the two materials I had to be careful to not cut the vulcanite deeper than the brass. The idea was to make a smooth transition between the two materials on the stem.

The next photo shows the condition of the top rim of the bowl. I decided to top the bowl and then rework the rounded edge to keep the acorn shape intact. I set up a piece of sandpaper on my flat board and turned the bowl into the sandpaper. I worked it and sanded it, repeatedly checking the flatness of the rim and also the amount of briar I was removing from the rim.

Once the roughness was smoothed out I sanded the rim with 220 grit sandpaper and a medium grit sanding block to smooth out the top and to round the outer edge of the rim to make it less abrupt and more like the original shape. The next two photos show the rim after the sanding and shaping with the sanding block.

At this point in the process I put the bowl into an alcohol bath and let it soak overnight to remove the varnish finish that was spotty and damaged. The next morning I took it out of the bath, dried it off and cleaned out the shank and the shank. The first photo below shows the bowl after I removed it from the bath. The second, third and fourth photos show the bowl after drying.

I restained the pipe with a Danish Oil Cherry stain applied with a cotton pad. I need to be able to work the stain into the deep rustication and also on to the smooth portions of the shank and rim. The rim took several applications to match the rest of the bowl.

I put the bowl aside to dry and worked on the stem. I sanded out the remaining scratches around the brass band on the stem with 220 grit sandpaper and then reworked it with the medium grit sanding block. Once the scratches were no longer evident I worked on the stem using the micromesh sanding pads from 1500-12,000 grit to polish the stem and prepare it for waxing and buffing. Once I finished with the 12,000 grit pad I gave the stem a coat of Obsidian Oil to seal the surface and to soak deeply into vulcanite. I buffed the stem with White Diamond to finish the shine and then reinserted it into the shank.

I buffed the entire pipe with White Diamond and gave it a coat of Halcyon II wax for rusticated pipes. I then buffed it again with a clean flannel buff to raise the shine. The photos below show the finished pipe.

Medico Ventilator — Unventilated (Thanks Ed for the idea)

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When I read this post by Ed James (Ozark southpaw) on Pipe Smoker Unlimited. This is the link to his post: http://pipesmokerunlimited.com/showthread.php?3186-Medico-Ventilator-unventilated I thought I would love to try that as well. Here is Ed’s first post in that thread that got me started thinking about the project. Ed also is a refurbisher of long standing and does excellent work. Here is his website: http://www.ozarksouthpawpipes.com/index.html

On PSU Ed wrote; “I’ve had a few of these and they smoke fine, although sometimes it was hard to get the filter seated so the pipe will draw as it should. If you’re not familiar with the Ventilators, they cannot be smoked without a filter. I smoke mostly filtered pipes, but thought I would see if I could make a Ventilator filterless. Accomplished it by turning a piece of briar the length of the shank and epoxying it in place. For the stem I used a vulcanite blank after replacing the tenon with delrin and adding a ring of tortoise shell acrylic. On my third bowl in it and it is smoking fine.”

Here is the pipe – pictured below. It is a nice looking sandblast that Ed “unventilated”.

So today was the day that I got to finally work on “unventilating” one of my own. Mark Domingues (dogtalker) recently sent me a few old bowls and pipe parts that needed some work. In that package was a Medico Ventilator. It was not as nice as the one Ed worked on, pictured above, but it was a Ventilator sans stem nonetheless and it was the opportunity I was looking for to try my hand at unventilating the Ventilator. This bowl was absolutely clean. I don’t think that it had been smoked other than maybe the first light or so. The bottom 2/3s of the bowl was still virgin briar. The bowl had the typical Medico lacquer coat and there were carved leaves all around the outside of the bowl. I decided to leave the finish alone and rework it as it stood. One day I may remove the finish but for now it will remain as it is.

I have kept a few unredeemable bowls around in my box of stuff and they came in handy this time. I took two different bowls out of the box and used a hack saw to cut off the shank as close as I could to the back side of the bowl. My plan was to follow Ed’s instructions noted above about turning a piece of briar to fit inside the Ventilator tube. I do not have a lathe so I decided to repurpose some briar shanks to do the same job.

After cutting them off the bowl they were ready for me to begin shaping them. I used a Dremel and sanding drum to take the diameter of the cut off shanks down to the diameter of the tube on the Medico. The next seven photos show the process of removing the excess briar. I used two different pieces of slightly different lengths that could be used depending on the stem I chose to use. The one pictured in the first seven photos below was about ½ inch shorter than the length of the tube. I thought about using a plug in the bottom of the tube but later decided to use the longer of the two briar tubes.

I used both the Dremel and 220 grit sandpaper to shape the briar tube to fit in the Ventilator. The first one was just briar. The second one was off of a screw mount shank. I decided to leave the aluminum in the shank and use that to but up against the aluminum seat in the Ventilator tube.

I sanded both tubes so that I could try both and see which one I wanted to use. I chose the long of the two with the aluminum base. I inserted it in the shank of the Ventilator with the aluminum end in first. I pressed it into place in the tube. It is a pressure fit so I did not need to glue it to fasten it in place. I chose not to use epoxy or glue to hold it in place and opted instead for a tight fit. Once in place it was slightly longer than the tube. The aluminum was tight against the interior and could go no further. I used the Dremel with the sanding drum on it to remove the excess briar. Once was flush against the aluminum it was time to fit a new stem to the shank.

I had several saddle stems in my can of stems that would work on the new shank insert. I turned the tenon down with a PIMO tenon turner until it was close to the right size and then finished with sandpaper and files. I used a file to shape the seat in the insert so that the stem would sit well against the tube. The next three photos show the newly seated stem in place.

I took the photo below to show the fit of the briar tube in the aluminum shank. There was a small divot out of the edge that is visible at about the ten o’clock position on the shank. This would be smoothed out as I beveled the inner edge of the shank inward.

I beveled the shank inward with small round needle files to give the stem a proper seat in the shank. I used some cherry aniline stain to stain the briar shank inset in the fins on the aluminum. I applied the stain with a cotton swab and wiped it off. I sanded the aluminum with micromesh sanding pads. I used the 1500 and 1800 grit to polish the aluminum and remove the scratches that were present on the shank.

I sanded the stem with a Dremel and sanding drum and then with 220 grit sandpaper to bring the diameter down to match the shank. I continued to sand until the scratches were minimized. Then I progressed to sanding with the micromesh sanding pads. I wet sanded with 1500 and 1800 grit and then dry sanded with the remaining grits of pads from 2400-12,000 grit. I decided to fit an acrylic ring on the stem with a slight ridge to match the slight ridge at the junction of the aluminum and the briar near the bowl. I liked the look of the black blue ring so I epoxied it in place. It began as a square piece of acrylic that had been a spacer on another stem. I shaped it with a Dremel to build a slight ridge that would parallel the one on the front of the aluminum shank.

With the spacer glued in place the new look of the stem was more complete to my eye. The stem still needed a lot of sanding and shaping. I used the 1500 and 1800 grit micromesh sanding pads once again to sand the newly added ring and the stem. I worked through 2400 and 3200 grit sanding pads to give yet more polish to the stem. I wet sanded right through 3200 grit this time, something I rarely do to polish the ring and the stem. I continued to dry sand the stem to a shine with the remaining grits of micromesh sanding pads (3600-12,000).

Once the sanding was finished I buffed the stem with White Diamond on the buffing wheel and then gave the pipe and stem several coats of carnauba wax and buffed with a clean flannel buff to give it a shine. The finished pipe is pictured below. It is now a working pipe – an “unventilated” Ventilator. Thanks Ed, for the great idea on doing this Ed. It was fun to figure out how to make it work. Your “groundbreaking” made it much easier however!! Again I say thank you.

I had no idea Douwe Egberts made pipes

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Blog by Steve Laug

When I posted the find of this pipe on Twitter, I received an email from Al Jones (upshallfan) that pretty well summarized my thinking. I post a bit of that email here: Douwe Egberts pipe??? We used them for our restaurant coffee program for many years (they provide the on-demand brewers used by Burger Kings as well). They are now owned by Sara-Lee. Who knew they made pipes! I’ll look forward to that restore and history lesson… If I had thought a bit more about it I would have remembered that Amphora tobacco was once made by Douwe Egberts but I did not remember that.

The one I picked up is a nice rusticated briar billiard. It is stamped Douwe Egberts X-tra 819. The stem also has a logo – an upward pointing white arrow-head. The bowl had a thick cake and the rim had a buildup of cake and tars. The bowl had what appears to be a combination of sandblasted and rusticated finish. The shank is sandblasted and it appears that the bowl was rusticated first and then sandblasted afterwards. The rustication has a rough edge appearance to it like it was blasted after the patterns were cut. The finish was dirty and worn and the stem had hints of oxidation under the grit and grime. There was minor tooth chatter on the top and bottom of the stem near the button. In the photo below, taken on my iPhone the pipe I am speaking about is the second one down from the top of the photo. (I apologize for the blurriness of the photo.)

Wikipedia states that Douwe Egberts (often abbreviated as DE) is a Dutch corporation that processes and trades coffee, tea, and other groceries. Its full name is Douwe Egberts Koninklijke Tabaksfabriek-Koffiebranderijen-Theehandel NV, which translates as “Douwe Egberts Royal Tobacco Factory – Coffee Roasters – Tea Traders, Plc.” http://en.wikipedia.org/wiki/Douwe_Egberts

The late Bob Runowski (Morelysson) had this to say about the brand: Douwe Egbert was a conglomerate which used to manufacture Amphora. I don’t recall if the conglomerate ever owned pipe manufacturing. DE offered pipes as a premium for coupons in Amphora Pipe Tobacco, I think in the ’60s. Strange to me, though, because their Amphora pipes were always stamped “Amphora”. I did smoke a fair amount of Amphora Brown in my time. It was quite common for most tobacco firms to offer some inducement for the smoker to continue to buy their products. One of the better known was the Reynolds offerings for PA and CH users. H&H used to include a pipe tool (tamper/knife).

As Bob spoke of above, I have seen DE offering pipes with Amphora coupons. But those pipes were consistently stamped Amphora –and sometimes X-tra as the DE one I have is stamped. Generally they also bore the Made in Holland stamp as well. This pipe is not stamped with any other than the Douwe Egberts stamp.

I reamed the bowl with a PipNet reamer to remove the cake, taking it back to bare wood. This pipe had a heavy aromatic smell so I decided to go back to the beginning and clean it out. Once I had reamed it I dropped it in an alcohol bath to soak for several hours.

I dropped the stem in a Oxyclean bath while the bowl was soaking. The Oxyclean softens the oxidation and makes it much easier to remove.

After a two hour soak, I took the bowl and the stem out of their respective baths and dried them off. In the first photo below you can see the oxidation has all risen to the surface of the DE stem. It is the third stem from the top in the photo.

I pushed the stem back into the shank once the shank had dried out and took some pictures to show the state of the pipe after the soaks.

I scrubbed the exterior bowl and shank down with a soft bristle tooth brush and Murphy’s Oil Soap to remove the grime and build up in the grooves of the finish. I also scrubbed top of the rim with the tooth brush and used a dental pick to remove the buildup from the grooves of the finish. Once I had scrubbed the bowl I rinsed it with warm water under the tap. I scrubbed it with the warm water to remove the soap and then dried it with a soft cloth.

I wiped the bowl down with acetone on cotton pads to clean off the remainder of the finish on the pipe. I worked on the rim until it was clean and free of the buildup that was deep in the grooves.

I restained the bowl and shank with a dark brown aniline stain, flamed it and then gave it a coat of Linseed oil with a light cherry stain.

This time around in the cleaning process I had gotten ahead of myself and stained the pipe before I had thoroughly cleaned out the interior of the pipe. IT WAS AN ERROR. Normally I clean and scrub the interior the same time I do the outside. It makes the cleaning with Everclear much easier and if the alcohol drips on the surface no harm is done. Doing it after the staining made the cleaner process fussy and I had to be careful not to harm the finish of the newly stained bowl and shank.

Once the interior was cleaned I set the bowl aside and worked on the stem. I sanded the stem with a fine grit sanding sponge to remove the surface oxidation. The Oxyclean had done a great job in bringing it all to the surface.

I put the stem back in the shank and did some work on the tooth marks on the top and bottom of the stem. I flamed them with a Bic lighter to lift them as much as possible. On the top side the marks disappeared altogether between the light sanding and the flame of the lighter. On the underside one deeper bite mark remained. I continued to flame it and sand until I had minimized its appearance on the stem.

I dry sanded the stem with micromesh sanding pads from 1500-12,000 grit. Each successive grit removed more of the scratches on the vulcanite and brought a deeper shine to the stem.

I rubbed down the stem with Obsidian Oil and set it aside to dry and soak into the stem and buffed it by hand.

I took it to the buffer and buffed it with White Diamond and then with carnauba wax. I gave it multiple coats of wax and then buffed the pipe with a soft flannel buffing pad to give it a shine. The finished pipe is pictured below.

Louis Blumfeld 1901 BBB Bent Billiard – by James Gilliam of jsecpipes.com

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When James posted his work on this pipe on the pipe forums I was amazed at how beautiful it looked. Wow a 1901 BBB – one of my favourite pipe makes and one of the old ones as well. Imagine the surprise when I got an email at the same time asking if I would like a write up and photos of the restemming for the blog. I did not have to think twice to answer that email. I quickly fired back an affirmative and what you have below is the story from James. Thanks again James for taking the time to document your work on this old timer. Enjoy smoking that great piece of pipe history. Below is his tale.

Every story has a beginning and this one even has a pre-story. The excerpt below was posted on several forums I’m a member of so I thought I would repeat it just for those that haven’t seen the posts.

“As some of you know I attend the 100km van Ieper in Belgium nearly every year since 2002. It’s a walk around the WWI Battlefields that consumed Ieper. I’ve been bitten by the pipe making bug, and how and along the way dabbled in restorations just because, but my search for a pre-WWI era pipe is finally over. I ended up getting this piece of history from Alan at Reborn Briar. Now he did the pipe restoration.. and a brilliant job he did, the only thing the pipe was missing was a stem.. well I can do that… I decided not to bore out the mortise and left it threaded, made a threaded tenon out of horn, since I don’t have any workable bone, and decided against using Ivory…… and went with Cumberland for my stem material.. I’m happy…Happy Columbus Day everybody”

Now for the rest of the story. What sticks around in usable condition for over 100 years… not too much, but since I’m kinda into this pipe thing, tobacco related history rates up there for my interest factor. This past July I was able to attend the Newark (UK) Pipe show, set up a table and sell some pipes. You never really sale (or at least I don’t) all the pipes you want to sale, but you do get to meet a lot of really interesting people, and the next table over was Alan Chestnutt from Reborn Briar. I’m always amazed at the folks like Steve and Alan that get into the restoration business. I’ve done a few, even wrote an article about it, but creation is where my passion lies.

Anyway, talking with Alan pre-World War I pipes came up, and fast forward to September he had one that he was going to restore but without a stem. As I mentioned above, stems are no problem…. that’s the making/creating/using machinery aspect I like. When the pipe arrived I was amazed at how well it looked. I mean wow, 1901, and all that.

The only real thing that threw me was the threaded mortise. Looking around the shop I pickup up a few of my mistake mouthpieces and tried fitting a few. The 7mm tenon fit without a problem, as it just slid into the mortise. But later that night while sitting around thinking about the mouthpiece I figured I’d make it as close to the original as I could. The stems profile was already in the leather case. So what do we know at this point.. 1900’s meant ivory, bone, or the like type of tenon. I don’t have any bone to use and didn’t really want to use ivory……but being a pipe maker I do have horn. I usually end up keeping the horn points after using the remainder of the material for a shank extension.

So horn it was to be. I shaped the tenon, drilled and set out to thread the tenon. I’m sitting with a 8mm tenon drilled to 4mm for the airway and went about threading the horn. Unfortunately it crushed under the pressure of my die, but I guess it only made sense… so I made another, except this time I threaded it first and then drilled it… And here is where the pictures come into play.

Threaded tenon, prior to drilling

And it fits just like it is supposed to. Looking right above the pipe you can see my trial delrin tenon with new threads.

Mouthpiece rough cut and drilled. The mortise is also threaded. I cleaned up the junction end before the next steps, so the fit would be flush

Epoxy’d and left to rest a while.

And it fits. So at least the scary parts are now done.

Drawing on the Cumberland to get my bearings at to decide where I want the saddle to sit. The line closest to the junction was chosen.

Time to sand a bit with a machine.

And done

Now it’s file time.

Now it’s sandpaper time.

And more sandpaper… I probably left a step or two out here…just to save the pictures, but my process is machine, medium cut file, fine cut file, another fine cut file, nail files, 180, 220, 320, 400, 600, 800, 1200 sandpaper, buffing paste, more sanding, high glass paste (Sometimes more sanding to remove scratches I missed) and a final buff. Here you can see the stem is bent to its final form.

And now it’s all shiny.

And here are the final pictures. Alan did the bowl, I did the stem and I have a pipe that is twice my age… gotta love it. Hope you enjoyed my story.

Restemming a Gift Pipe – a Savinelli Autograph 5

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On a recent work trip to Alberta I stopped by and visited Todd Bannard (aka Sasquatch) in his workshop. He did a bit of work on a Delrin sleeve for me and we smoked some bowls together. I left a couple of refurbished pipes with Todd and he gave me a Savinelli Autograph 5 bowl that needed to be restemmed. This afternoon I got around to fitting a stem to the pipe. The briar is a beautiful piece with a lot of gorgeous grain. The bottom of the bowl and the shank are sandblasted. The bowl has a plateau top and the shank took a flush fit stem. It had been barely smoked and certainly was not broken in. If it had been smoked one or two times that may be saying more than is true as the grain in the interior of the bowl is still quite visible. Below are some pictures of the bowl before I restemmed it.

I did research on the Savinelli Autographs to see what kind of stems they had and found a variety of them in pictures. About half of the photos showed a saddle stem with much the same proportions as the one that I chose to use. I went through my box of stems and found one that would approximate the look of the pipes online. I also wanted one that would fit after I turned the tenon. It would also take some minimal adjustment to the diameter of the saddle in order to align with the shank. I drilled open the airway to hold the guide pin on the Pimo tenon turner. I put it in the cordless drill and slowly cut away the diameter of the tenon until it was close to fitting in the shank.

I used a Dremel with a sanding drum to take down the tenon until it fit the shank. The next two photos show the newly cut tenon before I sanded it down to smooth out the marks left by the Dremel.

I sanded the tenon with 220 grit sandpaper and then with 1500 and 1800 micromesh sanding pads to smooth out the tenon. Once that was done the stem fit in the shank snuggly. In the four photos below the fit of the stem can be seen and the excess of vulcanite that needed to be trimmed away from the diameter is also visible.

I sanded the diameter with a Dremel and a sanding drum. I took off the casting marks left along the edges of the blade and on the sides of the saddle portion of the stem. I also used the Dremel to take off the excess diameter of the stem. I worked carefully and slowly along the joint of the stem and the shank so that I did not damage the briar with the sander. I was able to remove the majority of the overage with the Dremel and finished with sandpaper.

I sanded the Dremel marks out and further reduced the diameter with medium grit emery cloth. I sanded it until the fit was almost perfect. I would finish the fit with finer grits of sandpaper and the micromesh sanding pads later.

I set up a heat gun and the rolling pin I use to bend the stems next to it. I heated the stem with the heat gun set on the lower of the two settings. I held it over the heat until the vulcanite was flexible. At that point I bent the stem over the rolling pin in order to get an even bend in the vulcanite. Once it was bent to the angle I wanted I held it under the cold water tap in the sink to set the bend. The next four photos show the process and the resultant bend in the stem.

I took the newly bent stem back to the work table and did some more sanding on the diameter of the saddle to further match the shank. I used 220 grit sandpaper and a medium grit sanding sponge to clean up the stem and remove the scratch marks left behind by the emery paper. I scrubbed the bowl with Murphy’s Oil Soap and a soft bristle tooth brush to remove the dust and grit left in the sandblast portion and the plateau on the top of the bowl. I rinsed the bowl under warm tap water and dried it with a soft cotton cloth. I gave the bowl several coats of carnauba wax on the buffer before inserting the stem and giving it a light buff with red Tripoli. The next four photos show the status of the pipe and the new stem after the polishing on the buffer.

Next I sanded the stem with the micromesh sanding pads. I wet sanded it with 1500, 1800 and 2400 grit micromesh and then dry sanded with the remaining grits 3200-12,000.

When I had finished with the micromesh pads I gave the stem a coat of Obsidian Oil and rubbed it into the vulcanite. Once it was dry I buffed the stem and the bowl on the buffer lightly with White Diamond and then gave the pipe several coats of carnauba and buffed to a shine with a clean soft flannel buff. The pictures below show the finished pipe. It is now ready for the pleasure of breaking it in. I still have not decided what tobacco to use with it but there are several options on the table. I want to thank Todd for the great looking bowl to be restemmed and I will enjoy it and remember the visit to his shop.

Using a Delrin Sleeve to Repair a Cracked Shank

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I spoke with Mark Domingues via email regarding an old Peterson bent billiard he had with a cracked shank. We emailed back and forth regarding different ways of addressing the crack. Mark did not want to band the pipe as he liked the look of the briar and vulcanite sans band. We spoke of ways to repair the shank internally using a Delrin or aluminum sleeve that would be epoxied in the shank. The tenon would have to be resized to fit the new diameter of the shank. Mark responded by sending me the pipe to have a go at. I looked through my repair parts and found a white Delrin tenon that I had cut for me for a different repair I was doing. The tenon was almost the diameter of the inside of the shank, the mortise area. To achieve the fix I wanted to do it would need to be drilled out and turned down for a proper fit as a sleeve insert. The trick would be to allow proper space for the epoxy to be used to hold the repair in place. Too thick and the split in the shank would open up again. The sleeve would also need to be scored to give the slippery surface of the Delrin some bite against the inside of the mortise. I cleaned out the shank carefully with Everclear to insure that the interior surface was clean and I would be able to get a good measurement for the sleeve. Then I ran into a problem due to the lack of equipment I have available for this work. I had no way of anchoring the tenon to drill it out or to turn down the exterior of the tenon. I do not have a lathe which would have made the fix a very simple job. So I set the pipe and the Delrin aside and did a bit of thinking about how to proceed.

Several weeks later I was planning a work related trip to Calgary, Alberta and then later up into the northwest part of Alberta. I knew I would be passing by the area where Todd Bannard, aka Sasquatch on several of the pipe forums, lived. Todd is a pipe maker whose website is Briar, Sweat and Tears http://www.briarsweatandtears.com/ Todd makes some great pipes. I figured he would have a lathe. I gave him a call and asked if I could stop by for a visit and if he could turn a piece of Delrin to size for a shank repair. It would require him to drill it out and to also turn down the outer diameter to make a sleeve. Todd agreed to give it a go. I packed the pipe, stem and the Delrin in my bag and looked forward to my visit with Todd.

After our initial chatting and smoking a bowl together Todd had a look at the piece of Delrin I had brought along. He shortened the Delrin tenon to the proper length for the sleeve insert. He set up his lathe with a chuck to hold the tenon solidly in place and then inserted a drill bit in the other side. He advanced the bit slowly into the spinning Delrin until the airway opened up. He repeated the process with a second larger drill bit until the interior airway was opened as much as could safely be done with the bit. He turned the outside down to size, checking several times by inserting the Delrin into the mortise of the pipe. Once the fit was smooth and easy he reduced it slightly to give room for the epoxy that would also fill space. He turned grooves into the outer surface of the sleeve in order to give it some bite for the epoxy when inserted into the shank. With that done the rest was up to me. Todd and I smoked another bowl in his back yard before I headed out for the rest of my trip north. I cannot thank Todd enough for his willingness to use his skills and lathe to turn the sleeve for me. The next few photos show Todd’s set up on the lathe and his work in drilling it out and turning it down.

When I returned home from my trip to Alberta I set to work on the pipe. I laid out the pieces – the stem, the Delrin sleeve and the bowl in preparation for the repair. The first step for me was to open up the crack in the shank so that I could glue it together. I wanted the crack to bond together but no overdo the glue and harm the finish on the pipe. I inserted the stem in the shank and applied enough pressure to open the crack. I dripped clear superglue into the crack and then clamped it together until it dried. I used micromesh sanding pads to remove the excess glue on the shank.

With the crack repaired it was time to insert the Delrin sleeve. I mixed a two-part quick drying epoxy and put the sleeve over the end of an artist’s paint brush to make it easier to coat the outside of the sleeve with the epoxy. I used a dental pick to spread the glue on the sleeve and made sure that I had covered it completely. When the sleeve was evenly coated I left it on the paint brush handle and used that to press the sleeve into place in the shank. I adjusted the fit with a dental pick and set it aside until it was dry. The next two photos show the sleeve set in place in the shank.

After the epoxy set I used needle files to open the inside of the sleeve as much as possible in order to achieve a good fit for the stem. The original tenon had a smaller step down portion that was the perfect size for the sleeve. I carefully worked with a half round file and then with round files to evenly open the sleeve. When I had a good snug fit on the step down portion of the tenon I sanded down the rest of the tenon to match the smaller step down end. I used a Dremel, a rasp and needle files to reduce the tenon to the same size as the step down end. I worked on it until it fit snugly in the shank.

I sanded the tenon with 220 grit sandpaper to smooth off the marks left by the rasp and the files. I followed that by sanding the tenon with micromesh sanding pads until it was smooth. I used a sharp knife to smooth out the countersink in the shank of the pipe so that the transition from the briar countersunk portion and the end of the sleeve was smooth. The stem slid snugly into place and the repair was finished. All that remained was to polish the newly cut tenon to remove the marks of the files and sandpapers.

I buffed the pipe and stem with White Diamond on the buffer. I used a light touch so as not to damage the stamping on the shank and to polish the stem. Once finished I buffed it again with carnauba wax and a clean flannel wheel to polish the wax. The finished pipe is pictured below. The repair on the shank was done on the left side at the 9 o’clock position. The first photo shows that side of the shank. The crack is repaired and barely visible. The pipe should continue to serve its purpose for a long time.

A Unique Vertical Oval Shank Meerschaum Reborn

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I saw this old Meerschaum pipe bowl on Ebay and decided to put a low bid on it. I was not surprised to have won it and paid for it quickly. The seller packed it very well and shipped it off to Vancouver, Canada. Below are the Ebay photos that caught my attention. I think the thing that intrigued me the most was the vertical oval shank on the pipe. To restem that pipe would be a great challenge – find a stem large enough to work with and shape it until it fit. I thought I had just the stem in my box – a gift from a friend on Pipesmokers Unleashed Forum, Robert.

From the photos it looked to be in rough shape. The pipe case said it was a WDC but I have no way of knowing if that is true. The gold filigree on the band looks like the old WDC pipes of the late 1890s but I am still uncertain as to the maker. It was in rough shape as can be seen from the photos. There were many scratches and gouges around the outside of the bowl. The shank had marks on the top that looked like someone had taken a file to it. The rim was probably the worst. With the rough edges on the back right side of the bowl the rim/top appeared to be angled to the right side and worn down. The tar build up was heavy in the bowl and on the rim. The tenon was broken off in the shank. It appeared to be an old bone tenon and a bone insert in the mortise that was threaded to take the screw in tenon. I am assuming the pipe probably had an amber stem in its first appearance in the shop but that was long since broken and lost. The WDC case was also very rough – the edges were worn away, the wood broken and a hinge dangling unused. The inside was badly stained.

Yesterday afternoon I came home from work early and found a package awaiting me – I knew that the meer had arrived. I had to laugh when I cut open the box – it had a previous label a Funeral Home in Ohio. I don’t know if that was a commentary on the pipe bowl that resided inside the box or if a funny coincidence. I cut the tape and opened the box. The pipe inside was both in worse shape than I had imagined from the seller’s excellent pictures and in better shape. The meer under the band was cracked as can be seen in the photo above and that was as it was when it arrived. The scratches in the surface of the bowl were not as deep as they appeared in the photos and the pipe when place on the rim on a flat board was actually not slanted to the right – the damage to the outer edges of the right back side made it appear worse than it actually was in reality. The next photos show the pipe on the work table just out of the box.

After examining it carefully with my lens and a dental pick I decided to begin the clean up by trying to remove the tenon. I used the screw that I generally use to remove a tenon to no avail. The threads in the mortise were locked tight around the tenon. I picked at it with the dental pick and was unable to remove it that way either. I decided to drill out the old tenon. So I set up a cordless drill with a drill bit slightly larger than the airway in the broken tenon. I slowly drilled the airway with the bit and exchanged it for increasingly larger bits until I had the airway cleared of the debris. I then used a ¼ inch bit to open the mortise and clear out the remaining debris of the mortise and tenon. The second photo below shows the mortise after I opened it up. I used a dental pick to clean out the remaining pieces and hand turned the quarter-inch drill bit into the mortise to smooth out the walls of the airway and open it to receive a new tenon.

I took the pipe bowl back to the work table and set up a coarse sanding block on my worktable to top the bowl of the meer. I have used this block in the past with good success on the softer meerschaum material. I placed the bowl, rim down on the surface of the block and sanded it in a clockwise direction (no reason for that other than I am right-handed). I sanded it, checking often to see how the rim was cleaning up until the surface was clear and the top of the bowl once again level. Surprisingly I did not have to remove too much material from the rim to clean up the surface.

When I had finished the sanding, I used micromesh sanding pads to sand the top smooth once again and remove the scratches from the coarse sanding block. The micromesh sanding pads from 1500 – 12,000 grit bring a shine back to the surface of the meer and prepare it for rewaxing once the pipe is finished.

At this point in the process I decided to see if I could fit a new stem on the pipe. The diameter of the oval shank was quite large and would require a large diameter round stem. To make it an oval stem would require that much of the existing vulcanite of the stem would have to be removed in the shaping process. I had an old Brebbia stem that a friend on Pipe Smoker Unleashed Forum sent me for an old Peterson that I was restemming. The tenon was too small for the Pete but too large for the old meer. I used a Dremel with a sanding drum to remove the excess material from the tenon until the fit was very close. The remainder of the fitting was done with a wood rasp and sandpaper. Once the tenon was finished I pushed the stem into the old meer to check on the fit of the tenon in the newly opened mortise. As can be seen in the photo below, the fit was perfect. You can also see from that photo how much work would need to be done to fit the stem to match the shank of the pipe.

The stem had deep bite marks on the top and the bottom near the button. They did not break the surface of the vulcanite. I decided to heat the surface of the stem with a heat gun and try to lift the dents from both sides as much as possible. I also wanted to straighten the stem significantly to give a better profile to the pipe. The heat gun worked to achieve both aims. The tooth marks lifted quite a bit and would have to be filled with black superglue to finish the work and the bend straightened to the angle I wanted for the new stem.

I sanded the initial excess vulcanite off the diameter of the shank with the sanding drum on the Dremel. Once I had removed a large portion I took it back to the work table and used a rasp to continue to shape and reduce the stem to the right proportions. The next series of eight photos shows the effectiveness of the rasp in shaping the stem. (In the midst of the shaping my daughters brought down a bowl of popcorn for a snack while I worked – that appears in several of the photos.)

I removed the stem from the shank and cleaned up the tooth dents so that I could fill them with black superglue. The glue takes quite a bit of time to cure so I waited until I was finished for the evening and then filled the dents and set the stem aside to cure over night.

This morning I sanded the stem with 220 grit sandpaper and also sanded the superglue patch on the underside of the stem. The next four photos show the stem as it begins to take shape and the repaired spot on the underside of the stem. The oval is coming along nicely but there was still a lot of excess material that still needed to be removed.

I continued to sand the stem to further tune the shape of the oval to match the shank. I used 220 grit sandpaper to remove the excess and shape the stem. I worked on the superglue patch on the underside of the stem with the 220 grit sandpaper as well. In the next series of three photos you can see the shape I am aiming for with this stem. You can also see the size of the patch on the stem. The patch is still larger than the marks it covers so more sanding will need to be done on it to blend it into the vulcanite.

I cleaned up the bite marks on the top of the stem and applied the black superglue patch to that surface as well. I set it aside while I worked on the bowl. I wiped the bowl down with Murphy’s Oil Soap on a cotton pad to clean off the grime on the surface while leaving as much of the old patina as possible. The first photo below shows the superglue patch. I applied it and used a dental pick to push it around the surface and also build up a few tooth marks on the edge of the button. The second photo below shows the patch after it had dried and I had sanded the patch with 220 grit sandpaper.

While working on the stem I decided to open the button to make it simpler to insert a pipe cleaner. I used needle files to make the slot larger. The second photo shows the opened slot in the button. I sanded the inside of the slot with a folded piece of sandpaper to smooth the surface and polish the slot.

I took the pipe back to the Dremel and sanding drum to remove more of the excess vulcanite. I had the basic shape in hand and just wanted to get it closer to the size of the shank before doing the finish sanding. I brought it back to the work table and sanded with 220 grit sandpaper until the fit was right. The next four photos show the progress in the fitting of the stem.

I sanded the stem with a medium grit sponge backed sanding pad. It helped to remove the scratches left behind by the 200 grit sandpaper. Then I sanded the stem with micromesh sanding pads from 1500-12,000 grit to polish and shine the vulcanite and the patched areas. The white Lucite band that was a part of the stem began to take on a shine as well in the process. The next nine photos capture what took about an hour to achieve in the sanding process. I wet sanded with the 1500, 1800 and 2400 grit sanding pads and dry sanded with the remaining grits of micromesh.

I buffed the stem with White Diamond and a blue plastic polishing compound to bring out the final shine on the stem. I hand waxed the meerschaum with beeswax and hand buffed it with a shoe brush. The next four photos show the finished pipe with the new stem. I like the marks and scratches in the meer as they seem to speak of the long journey the pipe took to get to me. The white Lucite band on the stem fits nicely in my thinking against the gold of the filigree band. The slight bend it the stem works nicely for me. From the last two photos you can see the oval shape of the stem now that it is completed. It has come a long way from the round stem I received as a gift from Ron.

Adjusting a Misaligned Tenon

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On the old Churchill’s bent pot I picked up on Ebay and wrote about in a previous article I spoke of adjusting a misaligned tenon to tighten up the gap between the shank and the stem. Al Jones commented in his reply to that blog post that he would like to hear more about the procedure I used to achieve the correction. I have written this article in response to Al’s question.

The Churchill’s pipe had a slight cant to the tenon. It did not allow the stem to line up correctly. It had a gap at either the top of the bottom of the shank and no matter how it was inserted you could see light in the gap. I have seen the mishaps, and experienced some firsthand, when the tenon is pressed after heating to try to expand it. The misalignment is often dramatic and hard to repair. In the past I have had to just start over with a different stem. I decided to experiment with a different fix on this old Churchill’s.

My first attempt at heating the tenon involved the boiling water method that is used to bend stems. I set a bowl of water in the microwave and heated it for two minutes and then dipped the pipe stem, tenon first, into the water to heat it. I repeated that several times until the tenon was pliable and then dried it and inserted into the mortise. I pressed it into place carefully and held it while I cooled it. The results of the first attempt are below – still a gap and the addition of an oxidized stem to remedy. As I thought about the process and the desired end I concluded that a possible issue was that I had not heated the tenon enough to truly get a flexible bend to it. The caution is to proceed very slowly in the process so that you do not snap the tenon and necessitate a different fix.

I put the tenon in the shank and left a gap of approximately a ¼ to a ½ inch. I then used heat gun with a tip that reduced the area of the heat to about an inch diameter circle. I held the pipe above the heat and rotated it quickly to evenly heat the gap, and thus heat the tenon. I apologize for the blurriness of the photos but the general set up is clear. Hold the pipe above the heat about three or four inches, rotate it quickly as you do not want to burn the vulcanite.

Once the stem was warm I carefully pushed it into the shank. You want the stem warm enough that the tenon is flexible and not stiff or it will break off as you work it. The tricky part is to slowly and evenly push the stem into place. A variation in the push to either side will only make the problem worse. Once it is tightly against the shank I gently moved it until the fit was tight between the shank and stem. I held it tightly in place with my thumb and fingers as I cooled the stem and shank under cold water to set the new adjustment. It took several attempts to get it to sit properly.

Once the cooling was done I held the stem in place for a few minutes as I walked back to my work table. The finished fit was snug and no light shone through the stem shank union as it had previously. I have included the last three pictures below to show the finished fit of the stem to the shank. You can read about the restoration of the pipe in another blog post on the Churchill Bent Pot. https://rebornpipes.wordpress.com/2013/09/08/churchills-bent-pot/

Churchill’s Bent Pot

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Blog by Steve Laug

I saw this pipe come up on Ebay and love the shape. Some have called it a bent pot but I am not sure that the name captures the shape but I will call it that nonetheless. Churchill’s was not a brand I was familiar with but it looked very good. The stamping on the pipe is very simple on the left side of the shank it is stamped Churchill’s and on the right side it is stamped Matt Grain. The bowl had been reamed back by the seller before shipping and was well done. No damage to the roundness of the bowl. The inside of the shank was filled with chips of carbon from the reaming and they were stuck in the tar in the shank. The buildup was enough that the stem did not seat in the mortise and there was a gap in the fit of the stem and shank. The rim had some tarry buildup. The stem sat at an angle to the shank as if the tenon was bent slightly. There were three deep tooth marks on the top and the bottom of the stem near the button. The oxidation was present but not heavy at this point. The stem was also plugged with tars and the airflow was very constricted. There was an old English style C stamped on the stem. The first nine photos below were provided by the Ebay seller.

I am fairly certain that the pipe came from Churchill’s Tobacco Shop in Norwich, England. I found the following information on the Pipes and Logos website http://pipephil.eu/logos/en/logo-c4.html On the site there is a small paragraph which I have copied as follows: “Churchill’s Tobacco shop is situated in St Andrew’s Street at the corner of Bridewell Alley in Norwich, England. The shop was next to a church and at the bottom of two hills, and that’s how it became “Churchill’s”. Former manager: John Elvin (retired on May, 31 2008). Current owner (2008): Keith Garrard.” I have included these pictures from that website as they show the stamping on both the shank and stem that is identical to the pipe that I have just refurbished.

According to the Churchill’s website it is the last remaining specialist tobacconist in Norwich, originally standing at 32 St Andrews Street for over 23 years. http://www.churchillsofnorwich.com/index.php?_a=viewDoc&docId=1 The site also notifies the shop’s clients that Keith Garrard, who had a wealth of knowledge and was an avid pipe and cigar smoker himself, passed away on 23rd March 2012. His wife Coral continues to maintain the business in his honor.

I decided to try to remedy the bent tenon on the pipe to begin with. I heated it in a cup of boiling water to try to adjust it and tighten the fit in the mortise. I was able to adjust the fit and get a good tight seat with no gap between the shank and the stem. However, in the process the water oxidized the stem badly. The four photos below show the adjusted fit of the stem and also clearly show the bite marks on the stem – top and bottom near the button.

I scrubbed the inside of the shank with Everclear and cotton swabs. I cleaned the airway with bristle pipe cleaners and then fluffy pipe cleaners. I continued to scrub it until the pipe cleaners and cotton swabs came out clean. I cleaned the rim of the bowl with saliva and a cotton pad until the grime was gone. It took a bit more than a cotton pad and saliva so I also used a very fine grit sanding block to knock off the remaining tar, being careful to not break the finish.

The stem took a bit of work as it was plugged with grit and tar. I used a dental pick to clean out the slot. To the right of the stem in the photo is some of tar and grit I picked out of the slot. I used a straightened end of the pick to clean deeply in the slot. I then used pipe cleaners soaked in Everclear and pushed them through the blockage. I also opened the slot with needle files to facilitate easy access with pipe cleaners. The slot was very narrow which also made the blockage hard to get at.

I sanded the stem with 220 grit sandpaper to clean up the surface around the bite marks. In the next three photos the bite marks are visible. I heated them to lift them as much as possible. The bite marks on the top were less troublesome than the ones on the underside. Fortunately the stem was quite thick so that the tooth marks did not go all the way through the vulcanite.

I picked the tooth marks clean with a dental pick and then used black super glue to patch the deep marks that remained. Once the glue had cured and was hard I sanded the patches with 220 grit sandpaper and then a medium grit sanding sponge to smooth out the surface and blend in the patch. The next three photos show the patch after it had been applied and after sanding.

I sanded the stem with micromesh sanding pads from 1500-12,000 grit to finish removing the oxidation and the scratches left behind by the various sandpapers I used. The next series of photos show the progress of the shine after each group of sanding pads.

I wiped the stem down with Obsidian Oil and rubbed it into the surface of the stem. Once it had dried I rubbed it and polished it with a shoe brush before taking the pipe to the buffer. I buffed it with White Diamond and then carnauba wax. I gave it a polish with a clean flannel buffing wheel. The next four photos show the finished pipe. I really like the way the matte finish came alive. The grain really pops. This was an easy refurbish as the finish was in very good shape under the top layer of grime.

Another Loose Stem Fix

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Blog by Greg Wolford

As I undertook this project I had no idea that Steve was writing and posting an article on tightening a loose stem. But when I saw it I figured that since this was a little different fix, and the pipe was already blogged about here, I would go ahead with the article.

If you have read the story of Big-Ben then you know I had to restem it. It was the first time I’d done this and the first use of my new tenon turning tool, too. So, in my haste and excitement I made a goof, one that Ric Farrah was kind enough to comment on: I had not cleaned the shank out real well before fitting the stem, leading to a loose new stem.

I tried beeswax and “smoking it in” but neither of these worked on this particular problem; as Steve noted often an application of beeswax and use will tighten up an estate pipe stem. But I suppose since this was just a goof on my part and the stem had not been for properly these solutions weren’t going to work.

I was aware of the tools sold for stretching a tenon, the pluses and minuses that Steve mentioned. But I wasn’t really inclined to buy one at this point, especially since I had another idea on what might work: a drill bit! So, since the two easy fixes failed I went down to the shop to try out this new-to-me idea.

I removed the stem from the pipe and checked the size of the air-hole against my set of drill bits. I thought I had drilled it out to 5/32 so this is where I started. However, I soon realized that I had drilled it at 9/64 so I took both of these sizes and the stem to the heat gun set up.

I almost always use leather gloves when I use my heat gun; things can get real hot, real quick. And since I was using steel drill bits I definitely wanted the hand protection. So, I donned the gloves and turned the heat gun on low to start stretching!

Now, the first thing I need to say here is when doing this you are inserting the blunt end of the bit that normally gets chucked into the tenon. The sharp end is the turning end, in your hand for this procedure. This part is very important.

I began to heat the tenon slowly, checking every several seconds on the progress; I only wanted it warmed enough to be slightly softened, not so soft that it could easily be deformed or badly bent. Keeping the tenon moving, I would take the smaller bit and try to insert it in the air hole until it went in. At this point I worked very gently to get the bit inside the tenon the entire length of the tenon, removing the bit/tenon from the heat. I kept the bit turning slightly while it was inside the hole so it wouldn’t stick. After about a minute I gently removed the bit and allowed the tenon to cool a few minutes before checking the fit, which ended up being too loose still. So, I picked up the larger bit and began the whole process over, this time resulting in a perfect fit: good and snug with no “play” or slipping but not too tight either. Finally, the new stem was fit properly!

I left of overnight and loaded it up the next morning, checking the for again; it was still perfect, like it had been made for it (a little humor there)! The pipe smoked good before the adjustment but it now smokes very well with a good fit on the stem, part of which I’m sure is in my head, not fussing or worrying about the bowl falling off.

I found this fix very simple and expect to use it again in the future: it was done with tools/items I had on hand and only required a bit of patience and slow going to do right. Of course if I’d applied that idea to turning the tenon to start with I wouldn’t have had to refit the the stem. But then I’d not have had the opportunity to try out this fix if I had done it right to start with either: I suppose that is the silver lining in this cloud of errors!

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