Tag Archives: fitting a stem

Pulling a Broken Tenon

Over the years I have had my share of broken tenons to remove. Some of them came from carelessness on my part but others I purchased that way. I took pictures of the process I use on two different pipes recently. The first was a little Barling with a broken tenon and a chewed stem. I ended up restemming this one. The second one was a Peterson 999 with a broken tenon that I hope to reuse the stem by drilling/tapping and inserting a new tenon to refit it.

Insert a screw part way into the airway on the broken tenon in the shank of the pipe. I use a dry wall or gyprock screw. I turn the screw in by hand. I do not want to expand the tenon at all I just want the screw to have a little bite to it so that I can use it to pull the tenon out by hand or with a pair of needle nose pliers. In this case in both pipes I was not able to pull out the tenon easily. Many times I am able to pull it out in a matter of seconds using this method. But both of these were exceptionally tight and immovable. I put them both in the freezer for an hour as I know that vulcanite and briar contract at different rates with a change in temperature. After an hour I removed the Barling from the freezer and was able to pull the broken tenon out very easily. I then unscrew the broken piece and lay it aside to use for a match on the new tenon I will cut as a replacement. It helps me to eyeball the fit. I also measure the mortise and set the tenon turner as closely as possible to the measurements. I then take the broken piece and slide it on the tenon turner to check the fit.

The tenon on the Peterson however, still did not budge after an hour in the freezer. I left it in for another half hour. Still it did not budge. I then dripped Isopropyl alcohol into the exposed mortise and hoped that it would work as a solvent to break the tenon free. I repeated this several times and left the pipe sitting with alcohol in it over night. The next morning the tenon still did not move.

I decided to not fiddle around with trying to pull the tenon. I used my small drill bit and began to drill out the tenon. I never start with the exact size of the tenon but rather work with the size of the airway and work my way up. I have found that in the process of working through the bits the tenon inevitably breaks loose or crumbles to pieces. In this case, by the time I got to the third drill bit, when I reversed it the tenon came out with the bit. You will notice that I also flattened the broken portion of the tenon on the stem so that the surface was flat and smooth. I wanted it to be ready for when I would drill it out or tap to receive the new tenon that I have ordered.

As I close this essay I want to just mention a couple of reminders:

Do not turn the screw into the airway to deeply as it does expand the airway and can actually crack the shank on the pipe. BE CAREFUL and go slowly.
Do not use a tool to turn the screw into the airway – do it by hand so you can feel the progress and the bite before damage is done.
If the tenon is stuck and immoveable in the first try put the pipe in the freezer for an hour or more to expand and contract the tenon and mortise. This usually works to break it free.
Should you have to drill it out – use a bit a little larger than the airway to begin the process and work your way up to larger bits. Do not use a drill bit that is the size of the mortise lest you damage the mortise.
Use a T handle hand drill not a power drill to do this as you can easily drill right through the bowl and ruin the pipe.

Barling Garnet Grain Small Bent Billiard 2034 Given New Life

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Blog by Steve Laug

I picked up this little Barling (transition era pipe so the Barling stamping is missing the “s” and is a script) in a lot I bought on EBay. It had a broken stem that was also chewed through on the end and not repairable. The tenon was still in the shank and was exceptionally tight. I put the bowl in the freezer for about 30 minutes and then used a screw to remove the broken piece from the shank. The key here is to not screw in the screw too much or you can crack the shank. I was able to easily pull it out as can be seen in picture 3. The finish on the bowl was rough on the top with tars and some denting. The sides of the bowl also had some denting. I cleaned the top of the bowl and removed the tars. I steamed the dents out of the top and bowl sides.

I wiped down the bowl with acetone to remove the grime and the waxes that were on the finish. When I had finished I inspected the shank area because the drilling was off a bit in the shank and the walls were thin near the top left. There were small hairline cracks that went through several places and spidered up to about a 1/8 inch into the length of the shank. I glued those and pressure fit a nickel band on the shank.

I turned the tenon on a recycled stem I had here and fit it on the pipe. I used my Dremel to remove the excess material where the diameter of the stem was greater than that of the pipe. I kept the broken stem near at hand to match the diameter, the flow of the stem and the shape. I used it as a bit of a template to shape the new stem. The three pictures below show the process of shaping the stem from Dremel to hand sanding with 240 grit sandpaper.

In the picture below I have finished the initial shaping with the sandpaper and have a good fit. You will notice the lightening of the shank below the band – that is part of the process of sanding to fit the band to the shank. I place the original stem below the pipe in the picture for comparison sake. It is a bit thinner in profile than the new one in this photo. I continued to sand the stem with 400 and 600 grit wet dry sandpaper and water to remove the remaining scratches and grooves that the 240 grit sandpaper left. Once I had them removed I proceeded to use the micromesh pads – 1500, 1800 and 2400 grit to sand the stem smooth. When I finished with those I buffed the stem with Tripoli and White Diamond and finished by returning to the micromesh pads -3200, 4000 and 6000 to polish it. One more trip to the buffer with White Diamond finished the polishing. I gave the stem a coat of Obsidian Oil and removed it and set it aside. It was time to work on the finish of the bowl.

I used an oxblood aniline stain to match the stain to the original Garnet Grain colour. I have done this in the past and compared it to a very nice original Garnet Grain and the colour is a perfect match. Before staining I polished the bowl with the 3200 and 4000 micromesh pads avoiding the stamping on the pipe. I applied the stain with a cotton swab and then wiped it off, applied and wiped it off until I got the colour I wanted. I then flamed it and set it aside to dry. Once it was dry I put the stem on it and took it to the buffer and gave it a buff with White Diamond and carnauba wax.

In the first picture below I put the original stem in to show the damage to the underside near the button. I also put a 1 cent piece, a penny in to give perspective on the size of this diminutive billiard. I am very pleased with the overall look of the pipe. The finish came out as a perfect match to the original Garnet Grain colour.

A Barling’s Frustration

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I had this old bowl in my box that just looked like a Barlings. I took it out and studied under bright light and a loop. It had the arched Barlings over Make. The other side was stamped EL and Made in England (I believe). It had a serious crack in the shank so I superglued it and banded it. This little pipe became the definition of frustration for me. It was a beautiful and I was incredibly hopeful when I cleaned it up and prepared it for the new stem I had cut for it. The grain was very nice and to find that it was an older Pre-transition Barling’s pipe was exciting. The bowl cleaned up very well. The shank and new band looked great. All that remained was to finish working over the stem for it.

About that time my wife came down to the basement where I was working on it and we decided to go for our Saturday morning walk about. We had planned to take the bus down to an area we like to visit and check out the antique shops. This is something that we both enjoy so I put the little Barling’s my pocket and brought along some sand paper to work on it while sitting and waiting for the bus. We had a good morning, went to the Vancouver Flea Market and even found a couple of older Peterson pipes that I picked up. We decided to have some lunch before going home so we walked over to a nearby Korean BBQ and ordered a nice lunch.

While we were waiting for our lunch I guess the pipe fell out of my pocket. I did not notice until the waiter stepped on something and I heard a crack. Well the long and short of it is when we sat down to lunch it had fallen out of my pocket and when the waiter stepped on it the shank cracked off just ahead of the band. I had a sick feeling as I picked up the pieces of the broken old timer. My visions of a nice older Barling’s Pot shape were pretty much crunched. I put the pieces on the table and looked them over as we continue to wait for the meal and I grumbled about my stupidity in not zipping the coat pocket and also about bringing it with me in the first place.

Once we had finished eating and headed home I had calmed down enough to think about what I would do with the pipe. I took the pieces to the basement work table and turned on a bright overhead light so that I could examine the damages. As I looked at the broken shank I could see that the wood was darkened, almost burned around the crack. It was almost as if the heat in the shank had found a flaw in the briar and followed it outward to the surface. It had not gotten all the way to the surface but was just under the outer layer of the finish. So it appeared that the crack was worse than I had imagined.

That helped me to get over being incredibly frustrated and disappointed in the broken shank. So I spent some time looking it over and decided I could work with it. I decided to turn it into a nose warmer. The saddle stem I had made was too small in diameter to fit so I had to cut another stem. I cut off the ragged edges of the break and used a piece of sandpaper on a solid board to face the shank again. I also drilled out the shank and opened it up enough to accept the new tenon. The tenon is a bit shorter than normal 5/8″ to allow a little difference between the opening in the bowl wall and the mortise. I re-banded the shank for a second time to strengthen the shank after the previous break. I fit the stem to the pipe and sanded and polished it to a shine. Then I buffed and waxed the “new” little pipe. I made it such that I can one day put a church warden stem on the bowl should I desire to do so. For now though it is a nose warmer with a short taper stem. Total length is 4 3/4 inches.

Here are some pictures of the finished pipe. I had pictures of the pipe before and after the break but somehow they were erased so this is all I have left to show. I hope you can imagine what it looked like with the new saddle stem before it broke. But if not, you can see the new version. I am also ordering a churchwarden stem for it so I can fit one of those to it as well. Should look great that way as well.

Replacing a screw mount stem

Old Croydon-Reborn

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I have spent a bit of time on this old Croydon Bent (Peterson Line of seconds I believe). In fact I probably spent more time than I should have done, judging by other refurbishers throw away buckets. Sometimes I just have to see what I can make of an old tired ugly looking pipe. It is a challenge more than it is a labour of restoration. In fact it could probably be argued that when I am done with this one it really no longer should be considered a Croydon at all. I suppose it is a matter of how far one goes in the process of restoration before it becomes a totally new work of briar. In my mind this one would probably qualify for the removal of the name – or at least a hyphenated name CROYDON-REBORN.

When I received this one it was in pretty rough shape. In the pictures below you can see the state of the finish on the bowl. There were places where pieces of the lacquer finish were peeling away and falling off. The stain on the bowl was spotted and variegated. Even the many fills all over the bowl had shrunken significantly and what remained were dips and divots in the surface. The rim was one part of the pipe that was in pretty good shape. It had some tar build up and a bit of blackening but no nicks and dents. That is actually remarkable given the condition of the rest of the pipe. The silver shank cap was split in half and torn from the stem being jammed in and out of the bowl. The P-lip stem was also marked with tooth chatter, was oxidized and dented.

I did not have any end caps in my collection of pipe odds and ends so I decided to put a regular nickel band on the shank as it was thin and weakened from the broken shank cap. I cleaned the shank end with alcohol and dried it out. I heated a band and pressure fit it on the shank. There was a small gap at the edge that I filled with wood glue to give stability to the shank. I probably should have waited to apply the band but the shank seemed fragile and I wanted to stabilize it before further work on the bowl.

I have never liked the thin Peterson type stems so I decided to restem it with a saddle fish tail stem. I used my PIMO tenon turner and turned the tenon close and sanded it to a good tight fit. I used my Dremel to take down the excess diameter of the stem and worked on the ridges and seams with the Dremel. I sanded the roughness of the new stem until it was smooth with 240 grit sandpaper followed by 400 and 600 grit wet dry sandpaper and a bit of water. It was finished with the regular regimen of micromesh pads – 1500, 1800, 2400, 3200, 4000 and 6000 grit. The final polish was done on the buffer with White Diamond and carnauba wax.

The bowl was a major problem. I tried to strip the bowl using acetone and 99% Isopropyl alcohol and could not break through the finish – don’t what they coated it with but it would not let go. I resorted to sanding the bowl to try and remove the finish and sanded, sanded and re-treated it with acetone and alcohol. The finish was finally gone and I had a raw briar bowl with so many fills in it that it looked like it had freckles. I decided to try staining it with a dark brown stain to hide the fills and give it a good deep colour that was a bit opaque. Once it was dry I buffed it and polished it with wax. It looked really awful and I hated it!!! Soooo… I decided to rusticate it. I used my fist full of nails (pipe with nails inserted in it) to do the rustication that appears in the photos below. The previous coat of stain that I had applied helped with the process of rustication and I could clearly see where I needed to do a bit more work. This is when I wished that the band was not present as it would have been a bit easier to avoid contact with the band and the rusticator.

Once the rustication was acceptable to me, and the pipe felt good in the hand I prepared it for staining. On this one that involved using the floral frog to knock off any loose chips of briar and to smooth out the surface before I wiped it down with a damp alcohol cloth. I also sanded the rim smooth and used the micromesh to get rid of any scratches. A smooth rim and a smooth spot around the Croydon stamping would look good on the finished pipe. I decided to go for an aged leather like finish on this pipe as it seemed to fit the shape and the look. I gave the pipe a coat of black stain as an undercoat and then buffed it off the high spots. I gave the entirety a coating of Fiebing’s Medium Brown for the top coat. I flamed it and after drying took it to the buffer for a light buff. I waxed it with Halcyon II and buffed it with a soft cloth to give it the final look. Below are pictures of the finished pipe. In my book it is a significant improvement over the original!

The 1912 BBB Poker

1 Reply

Blog by Steve Laug

I picked up this old 1912 BBB Poker on EBay not long ago. It is stamped BBB in a diamond on the shank and on the underside England. The silver is hallmarked Birmingham 1912. It is a smaller group 1 or 2 sized pipe. In the pictures the military stick bit looked like it belonged. It looked like it was shipped that way from the factory. The grime on the silver and on the shank as well as the oxidation on the stem made it appear to be that style of pipe. When it arrived with the other 5 pipes that I bought with it I examined it a bit more closely. In the picture below you can see the roughness of the stem. It is definitely poorly cut. The closer I looked the more I realized that it was a poor replication of an older stem. A BBB pipe of this age came with a different style of military stem and it had an orifice button rather than a slot like this one. The stick bit was not original as it was a slotted bit and was not finished smoothly. There were lots of file marks on both sides of the stem. When I removed the stem I was even more certain that it was a poor copy. The one thing I was still thinking was that it was definitely spigot or military bit pipe.

Then I began to work on the shank and the band. Someone had darkened the end of the shank to make it look almost black like the tarnished silver band. Once I cleaned the silver and cleaned the shank I could see that it was not a silver end cap at all but a very typical BBB silver band. In the picture below you can clearly see the end of the shank showing as it sits inside the silver band. I used a 1500 micromesh pad to clean off the end of the shank and return it to wood. When I re-stained the pipe I would also re-stain the shank end to match. It was clear that I would need to do a bit of research on what kind of stem was originally on this poker style pipe if I was to restore it to its original glory.

I have a copy of the BBB Catalogue reprint from Gary Shrier so I got it out and went to work researching the look of the missing original stem. It became clear rather quickly that the pipe shape I had originally came with a taper stem with an orific button. In the catalogue is the exact shape in the exact size. I could not believe it. I laid the bowl on the page and then traced out the shape and size of the stem. A part of my hobby refurbishing is collecting old stems. I buy them wherever and whenever I find them and stockpile them in an old coffee can in my office. I went and got the can and emptied it on my desk to sort through what I had. I have yet to organize them by size so it is a matter of dumping the can out and digging through them. Well, I found one in my can of stems that had the right orifice button and the correct taper so I turned the tenon and fit the stem to the pipe. I used my Dremel to remove excess diameter from the stem so that it was the same diameter as the shank and band.

I also had to clean up the bowl of the pipe as the top was pretty beat up and the inside rim had been chipped and cut as if it had been carelessly reamed with a knife. I steamed the dents from the rim and carefully did a minor topping on the bowl to bring the top back to smooth and the inner and outer rim to smooth. I also chamfered or beveled the inner rim to bring it back into round. There were also dents on both sides of the bowl so I steamed those out as well. I use a wet cloth and a hot butter knife (heated over a flame) to raise the dents. I finished the work on the pipe by re-staining the top to match the bowl then buffed it and gave it a final polishing with White Diamond and then several coats of carnauba wax.

Here are pictures of the finished pipe. Other than being in colour it is a perfect match to the one in the catalogue.

Edit – 24 Feb. 2013 – I just came across an old BBB poker on eBay that is similar to the one above. I did some research on the stem on the one above and restemmed it. The one in the eBay photos is a newer version of the same pipe number. I have attached two photos below for sake of comparison.

Fitting a pipe with a new stem – photo essay

1 Reply

Blog by Steve Laug

I picked up this pipe bowl – a Pete 207 – an early Peterson from the late 40s. It was in need of a stem. I have a couple of cans of stems that are precast blanks. They need to have the tenons turned to make them fit correctly.

I have a PIMO tenon turning tool like the one pictured in the diagram below. I have to drill the stems to fit the guide pin as they are generally very small. Once that is done with a bit on my cordless drill I then put it on the tenon tool and adjust the carbide cutter to the diameter tenon I want to cut. I always start large and work my way down. I have found that trying to cut too much off at once causes the tenon to chip or break. So I start large and work my way down until it fits the mortise. I found this YouTube link that gives a video presentation of the process so I have included that as well for your information http://www.youtube.com/watch?v=drKxzteEEPk A quick look at the video will show you the process I use in turning the tenons. I generally turn the tenon until it is close to fitting and then finish the fit by hand. I have found it is better to proceed by hand from that point so as I don’t take off too much of the vulcanite and have a loose fit on the tenon. I will show that process from the point the tenon has been fit in this pictorial essay.

Below is a stem blank that I picked up online from Pipe Makers Emporium. I have several coffee cans full of different sizes of blanks. I sort through them to find one that is close to the outside diameter of the shank. I find that it is not too difficult to get the two to match with a lot of sanding and fine work.

Below is a picture of the bowl prepped and ready for the new stem. I cleaned the top and polished the silver band as I want nothing in the way of a tight fit for the stem. You will also notice in the photo that the tenon is partially turned for a fit. I stopped at this point to show the process. The large portion still remaining on the tenon shows the first turn of the tool to take off the first portion of vulcanite. I keep the tool turning so that the carbide blade removes the face of the stem as well so that the seat will be straight and flush at the union of stem and shank. I find that when I do this at the beginning of the turn it give a good clean finish. The step down in the tenon shows the next portion removed. I have adjusted the tool to take off that portion. After this photo I finished turning the tenon.

The PIMO tenon tool took a bit of work for me to figure out the adjustments as I purchased the tool second hand without the instructions. The fellow I bought it from gave me some quick lessons on how to adjust it. He even threw in the hex keys!! So needless to say, I learned by trial and error how to adjust the cutting head and keep it straight for a straight cylinder cut on the tenon. Since then I have it has been pointed out to me that Kurt Huhn of Pipe Makers Forums has noted the tricks I learned the hard way.

I will try to capture the trick in my own words, combining what I have learned the hard way with Kurt’s recommendations. The first step in the process is to adjust the cutting head. Start by removing small portions at a time. To deep a cut makes the cutter wobble and give an uneven tenon. To adjust the cutting head insert the adjustment hex key (larger hex screw on the tool) and the lock key (smaller hex screw) into their set screws. Do not turn them, just insert them. Push in lightly on the adjusting key and pull up slightly. Loosen the lock key a quarter or half turn. While maintaining the up and in pressure on the adjusting key turn it in increments of a half turn (think half hour on a clock). With steady pressure on it by pulling it up, the arm with the carbide cutting head is not loose and wiggling as it is adjusted. If it is loose while adjusting it, you will get non-cylindrical tenons regardless of the number of turns from zero. Do not let go of the adjusting key, tighten the lock key while the pressure remains on the adjusting key. Pull the adjusting key straight out, being careful not to turn or press down on it. Trim the stem and repeat as you need to get a good tight fit on the tenon.

The next sequence of photos shows the tenon finished and the fit clean and tight. I hold it up to the light to make sure that there is no light showing between the stem and shank. Also note the Dremel with the sanding drum in the photo. I use that to bring the outside diameter of the stem to a close match to the shank. I run the Dremel at the middle speed to allow me more control of the tip as I take off material. If I run it too fast I find that it takes off too much. Too slow and it leaves a chunky beat up finish that takes a lot of sanding to smooth out. As can be seen from the photos there is not much material that needs to be removed for a smooth fit.

In the photos above I have used the Dremel and removed material to the point that the stem and the shank are almost level. I did it in stages with the stem on the shank and rotating the pipe to keep the perspective round and even. Once I got it to the stage above I move to my table and continue the rest of the work by hand. Sand paper in a variety of grades starting with 180 allows me to work the remainder of the material off and to get the scratches and grooves from the Dremel worked out of the stem.

Each of the next seven photos shows the progress of the stem toward the finished product with the different sand papers. Once I have removed the majority of scratches and grooves left by the Dremel with the 180 grit (pictures 1 &2) I move on to using 220 grit and 240 grit to take down more material. Care must be exercised to not scratch the band or the shank. The idea is to leave the shank exactly like it was without scratches or marks (pictures 3,4,5).

Pictures 6, 7 & 8 show the stem after using 1600 grit wet dry sandpaper. Each sanding step removes more material and evens the flow of the stem to shank. It also removes scratches and prepares the stem for the finish sanding.

The last four pictures show the pipe after sanding with micromesh pads – 1800, 2400 and 4000 grit. Generally each of the pads progressively polishes the stem. Any places that still show scratches send the stem back to the 600 wet dry sanding or even further depending on the depth of the scratches. When the polish is clean and smooth I take the stems to my buffer and buff with white diamond that raises a deep reflective finish on the stems.