Tag Archives: pipe restemming

An Earl of Essex Apple Reborn

This Earl of Essex pipe bowl was in bad shape. I had received the bowl without a stem so I would need to restem it if I was going to refurbish it. The bowl rim was angled down toward the front and was worn and rough. It appeared to be thinner in the front than the back of the bowl and had burn marks and rough patches on the front. The finish was shot and the aluminum insert in the shank was oxidized. The bowl had an uneven cake and was crumbling. There were several red spots on the surface of the rustication. What interested me in this old bowl was the rustication. The top of the bowl had almost a wax drip look to it with rustication between the drips of “wax”. The drip pattern is smooth briar as was the rim at one time. The end of the shank and the high spots on the shank were also smooth.

The aluminum inset mortise took a screw in tenon and I did not have any metal screw in tenon stems. I would have to drill it out to fit a new stem. I decided to try my hand at opening up the mortise with a drill. I started with a drill bit slightly larger than the mortise and then moved up with bigger drill bits until the mortise was smooth and open enough to take a new push stem.

I started to top the bowl but stopped mid stream and reamed the bowl with a PipNet reamer to clean out the cake. I wanted the bowl clean so that as I topped it I would be able to see how deep the damage to the bowl went.

Once reamed, I took it back to the topping board and sandpaper. I used 220 grit sandpaper and twisted the bowl top into the sandpaper in a clockwise pattern. With the bowl topped and the shank opened the bowl was ready to clean up.

I wiped down the bowl with acetone on cotton pads to remove the finish from the bowl and clean up the grime that was built up in the grooves of the rustication. There was a bright red pigment in the grooves on two sides of the bowl. I scraped at it with a dental pick to clean it up. At first I thought it might be putty but as I scraped it, it came off like a red pigment. I am not sure what the red material was. I wiped it down after scraping it.

I decided to stain the bowl with a contrast to set off the rusticated portion from the smooth portion of the bowl. I used a cotton swab and black aniline stain to stain the rusticated portions of the bowl. I wanted the black to highlight the areas between the smooth drip portions of the bowl. I stained and flamed it and repeated the process until it was a good even colour around the bowl. I sanded the smooth areas of the bowl with a medium and a fine grit sanding block and sponge to remove scratches and clean them up for the next coat of stain that would be used on the smooth areas.

I had several stems in my stem can that would fit the shank of the drilled out mortise. I tried a BBB stem first. It fit very well in the shank. The look was exactly what I wanted but I did not want to waste a BBB stem with the logo intact on an experiment.

So I used the second stem I had from the can. It was a saddle stem with a bite through on the top of the stem. I decided to cut it back and then reshape the button until it was a new stem.

I cut it back with a Dremel and a sanding drum until it was smooth, solid and straight across.

Before working on cutting the new button in the stem I stained the top portion of the bowl with a light walnut stain on the smooth parts of the bowl. I buffed the bowl with White Diamond to give it a shine.

I worked on the button with needle files cutting in the straight line of the inner edge of the button and then smoothed out the button itself with the files. I carved away the surface of the stem tapering it from the saddle to the button. Once it was cut with the files I sanded the new taper with 220 grit sandpaper and then with a medium and fine grit sanding sponge to remove the scratches on the vulcanite.

I sanded the stem with my usual array of micromesh sanding pads. I wet sanded the stem with 1500-2400 grit pads and dry sanded with 3200-12,000 grit pads. I rubbed down the stem with Obsidian Oil and buffed it with White Diamond.

I buffed the bowl lightly with White Diamond and buffed the stem with it as well. I gave it multiple coats of carnauba wax and buffed it with a soft flannel buff to give it a shine. The finished pipe is shown in the photos below. The bowl top is clean and new, the finish is redone and the wax drip look is highlighted with the stains. The new stem and the newly cut button fit the pipe well. The experiment of drilling out the aluminum shank insert to take a push stem was a success. The metal polished well and looks like a shank band. Overall the final product is nice looking pipe that will make a good addition to someone’s rack in the future.

Cutting Back a Broken Shank and Reworking a No Name Dublin

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In keeping with the theme of my last few posts about my recent pipe restorations the pipe I took on in this repair/restoration was in fairly bad shape. The rim was damaged on the top and the outer edge had been beaten badly and was rough to the touch. The inner edge had been reamed out of round somewhere in the distant past of its life. The bowl finish was “finished”. It was in rough shape. The left side had many fills and divots on the surface. It looked as if it had been dropped on concrete or rocks. The shank was much the same but worse in that the end on the top right side had a large chunk of briar missing. It did not have a stem but that was the least of the concerns at the moment.

I went through my can of stems and found one that would work. The diameter and length were correct for this size pipe. However I had to decide what to do with the missing chunk of briar. I could band it and cosmeticly hide the missing piece under the band or I could cut back the shank, shorten it and then band and restem the pipe.

I removed the band – this is slightly harder than the simple words sound. It really involved cutting the metal and peeling it off the shank. I was not happy with the look so I decided to cut off the damaged end of the shank. What made this a happy solution to me was that the shank itself was not cracked. There were no cracks radiating from the area of the missing piece of briar.

When cutting back a shank I use a small hack saw with a fine toothed blade to do the work. I am limited to hand tools as I do not have a shop. The problem with this method is that it is very difficult to get a good, clean, straight cut with a hand saw. I followed the scoring left behind by the band as I sawed around the shank.

Even in being careful and working slowly the shank end was not perfectly square. That would have to be dealt with later.

I needed to deepen the mortise area as I had removed a major piece of it by shortening the shank. I started with a drill bit that fit well in the existing mortise and turned it in by hand. I worked up to the correct size bit – each time anchoring the bit in my hand drill and turning the bowl onto the bit by hand. I did not want to risk using the power and having the bit go right through the bowl. I have a pin vise but it was not large enough to hold a bit this size so I improvised.

Once I had the airway drilled in the shank I set up a topping board to sand down both the end of the shank and the rim. I started with the shank end hold the bowl against the sand paper and making sure that it was straight up and down vertically and sanded the end of the shank to face it. I also topped the damaged rim to remove the damage to the surface and the edges of the bowl. I sanded the bowl down with sandpaper in preparation for the topping. The shank needed to be re-tapered to match the diameter of the stem and to give it more of a flow from the bowl to the stem. I used 220 grit sandpaper to taper the shank and to sand the bowl.

Once I had a good fit on the stem and the shank and the bowl was topped and the finish cleaned up I decided to put a band on the shank. I thought that the shiny bling of the band would be a nice contrast to the stain I intended to use. I heated the band and pressed it onto the shank.

With the band in place and the stem fitting well it was time to address the finish of the briar. The left side damage needed to be cleaned up and repaired. I picked out the loose fill material with a dental pick. I washed down the surface of the bowl with acetone on cotton pads to remove dust and clean up any loose pieces of fill material. I roughened the edges of the divots and crevices on the briar and then filled them with briar dust and superglue.

I sanded the repaired area with 220 grit sandpaper to remove the excess material and smooth out the surface of the bowl.

I sanded the bowl with medium and fine grit sanding sponges to remove the scratches and prepare the surface for staining. I wiped it down with isopropyl alcohol on a cotton pad to pick up any surface dust before staining. I am continuing to experiment with contrast stains so I gave the bowl a heavy coat of black aniline stain. I flamed it and heated it to set the stain deep in the grain of the bowl. This particular bowl had some really stunning birdseye on the sides and great cross grain on the front and back and underside of the shank and bowl. I wanted to highlight that grain and make it pop.

Once the stain was dried I wiped the bowl down with acetone on pads to remove the surface stain and then buffed the pipe with red Tripoli. I wanted to remove as much of the stain on the surface as possible while leaving it in the grain and around the birdseye. I sanded the bowl with medium and fine grit sanding blocks and sponges to get the surface down to the place the grain was highlighted. I then rubbed the bowl down with olive oil and buffed it with White Diamond to make the bowl shine.

I was happy with the contrast on the contrast stain and the look of the bowl at this point but now needed to work on the stem and the band. I sanded the stem with medium and fine grit sanding sponges to remove the scratches. I sanded the band with a fine grit sanding sponge as well. I then sanded the stem, band and the bowl with micromesh sanding pads. I wet sanded the stem with 1500-2400 grit pads and dry sanded the bowl with the same grit pads. I dry sanded the bowl and the stem with 3200-12,000 grit pads to finish polishing them both. I rubbed the stem down with Obsidian Oil and then when dry I buffed the bowl and stem with White Diamond.

The series of four photos below show the bowl and stem after sanding with the micromesh sanding pads. The finish on the bowl is exactly what I was aiming for. The translucency of the finish was perfect. The fills and damage on the left side of the bowl all but disappeared – not just hidden by the finish by smooth to touch as well.

I buffed the pipe one last time with White Diamond and then gave the bowl and stem multiple coats of carnauba wax to polish and protect it. I finished by buffing with a clean flannel buff to lift the shine. The finished pipe is shown below and is ready for its inaugural smoke. The bowl and pipe came out well in my opinion and should last a long time in the hands of the person whose rack it eventually will grace.

I just reworked the inner rim of the bowl. I did a write up on the process and posted it here: https://rebornpipes.wordpress.com/2014/03/28/repairing-an-out-of-round-bowl/

No Name Pot Brought Back to Life from the Brink

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This bowl came to me with a batch of bowls needing different degrees of work. This old-timer needed cleaning as the buildup of grime and grit that was ground into the bowl was thick. The surface was coated with a greasy black substance all around the top of the bowl and the sides. The bowl/shank junction was incredibly grimy. The inner rim was out of round and the outer rim and the top of the rim were in rough shape. The outer edge had been hammered around the sides and the top had dents and cuts in the surface. The shank looked to be slightly shorter than I have come to expect on this shape of pipe; though the drilling and the mortise were original. The shank had definitely not been shortened. The bowl was caked and the buildup thickest around mid bowl. There were quite a few small pink fills around the bowl sides. There was no stamping or identifying marks on the pipe. There had been some sanding done around he shank and it had left behind some fairly deep scratches.

I went through my can of stems and found one that fit quite well. It did not need work on the tenon diameter as the fit was snug. The stem was bent and would need to be straightened to give it a proper fit to the bowl. Once the stem was in place it was clear that the shank was out of round. The bottom edge of the shank was somewhat thicker than the stem at the same spot. I would need to work on the flow of the shank from the bowl to the stem union to insure that the fit was smooth and the transition seamless.

The stem was badly oxidized so I figured heating it to straighten it would actually soften the oxidation and bring it to the surface. I used a heat gun on the low setting to heat the stem. I generally hold it about 4 or more inches above the heat source and hold so it bends in the correct direction as it softens. In this case it did not take long for the vulcanite to heat and the stem to return to the original straight position. I decided to leave a slight bend in the stem as I like the look of on the pipe.

The next two photos show the stem after heating and straightening. The variation in the diameter of the shank and the stem is also clearly visible in these two photos.

Since the shank had no stamping to preserve I decided to sand the shank and the stem to even things out and to bring the shank into round. I used 220 grit sandpaper to remove the excess briar and to shape the taper on the stem. I sanded the stem as well to remove the softened oxidation and make the cleanup simpler.

I set up a topping board and anchored a piece of 220 grit sandpaper on the surface to provide a flat straight surface to sand the top on. I twisted the top into the sandpaper in a clockwise motion to remove the tars and rim damage on the bowl.

I wiped down the surface of the bowl with acetone on cotton pads to remove the grimy buildup on the finish. The black tarry substance took some elbow grease and hard scrubbing to remove. The inner rim would need some work to bring it back into round but that would wait until after I reamed the pipe.

I sanded the bowl with 220 grit sandpaper and medium and fine grit sanding sponges to further remove the finish and the grime. I worked on the inner edge of the rim with a folded piece of 220 grit sandpaper to bevel the inner edge into the bowl. This minimizes the appearance of the bowl being out of round. It also removes burn damage and smooths the look of the rim as a whole.

I decided to try something different on this bowl in terms of stain. It had some great cross grain and some nice birdseye grain that I wanted to highlight. It also had some ugly pink fills that I did not want to pick out and refill. This led me to try a black aniline stain. Before I stained it I used a black permanent marker – a sharpie to line through the pink fills. I blended them into the grain of the wood with the pen. I heated the bowl with the heat gun to open the grain and then applied several coats of black aniline stain, flaming the stain between each application. Once the stain was dry I wiped the bowl down with isopropyl alcohol on cotton pads and then sanded the bowl with a medium grit sanding block. I wanted to remove the black stain from the higher/harder areas of the briar while leaving it in the grain patterns.

I sanded the bowl with a medium grit sanding sponge and then wiped it down with isopropyl alcohol to remove the dust. I remarked the fills with the black Sharpie. In the four photos below the marked fills are visible and the finish has about all the black removed that I wanted to take off.

I rubbed the bowl down with Olive oil on a paper towel and rubbed it into the finish. I sanded the bowl with micromesh sanding pads – 1500-2400 grit, while the oil was wet as the oil gives the pads a bit more bite. I worked on the marked areas to blend them in with the sanding pads. I also sanded the stem with the micromesh sanding pads and the Olive oil at the same time. The next four photos show the finish after it had dried over night. I then buffed it on my buffer with White Diamond and gave the bowl several coats of carnauba wax. You can see how well the black sharpie blended into the finish. The pink fills have all but disappeared in the finish.

I sanded the stem with my usual array of micromesh – the difference this time was all pads were used to dry sand the stem – 1500-12,000 grit. In between each grit I rubbed the stem down with Obsidian Oil and rubbed it into the vulcanite before sanding with the next grit pad. Once I had finished with all grits I gave the stem a final rub down with the Obsidian Oil.

I gave the pipe several more coats of carnauba wax on the buffer and then buffed it with a soft flannel buff to bring out the shine. I was aiming for a stem shape similar to what I had seen on the Castello 55 shape and wanted that slight bend downward in the final look. While the pipe is certainly no Castello, I like the final look of the stem and the bowl. It certainly has come a long way from the bowl that came in the lot I received in the mail. This one should make a good addition to someone’s rack once it leaves here. The next four photos show the finished pipe.

It looked like someone took a saw to the bowl on this one – A Bruyere Garantie Lovat Restored

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This bowl came to me showing a lot of promise but also a lot of damage. It was like someone had sawed at the bowl on the side near the shank. The cuts were more than mere flaws in the briar as they were very jagged and broken inside the cuts. There were what looked like tooth marks in the grooves. I debated on rusticating it but there was something about the challenge that made we work at ways to make it smooth once again. The inside of the bowl was in great shape. There was one damaged spot on the inside edge of the rim on the right side of the bowl. The bowl had tobacco still in it and the top of the rim was tarred and caked. There were multiple nicks in the finish all the way around the bowl but the majority of those were in line with the deep grooves. The bowl came without a stem and the shank had a nick out of the end making a clean fit almost impossible. There were no cracks in the shank so no damage in that way. The stamping on the pipe is Bruyere in a curved banner – unfurled in an arch on the left side of the shank and underneath it is stamped Garantie. The banner also seems to go across a three pointed crown that is visible underneath the banner.

I found a precast stem in my can of stems that was close to the right diameter to the shank and turned the tenon with a PIMO Tenon Turner and then fit it in the shank. I used a Dremel to remove the excess rubber along the edges and end of the cast.

I sanded the stem and the shank to achieve a good smooth transition between the two. In the process I was curious as to what the shank would look like with a band so I slid a band part way on and fit the stem in place to have a look.

I liked the look of the band so I removed it and sanded the stem to fit smoothly against the shank. I sanded it with 220 grit sandpaper. (I have found that lower grits, courser sandpaper just makes for more scratches and is counterproductive when I am working toward refinishing the bowl.

Once I had the fit right and the transition smooth I cleaned off the shank with isopropyl alcohol and then rubbed on some white glue I heated the band and pressed it in place. With the band in place I took the bowl back to my work table and did a light topping as the outer edges of the bowl were more damaged than I thought. I wanted a good clean rim to go with the pipe once I had stripped and refinished it.

I reamed the bowl with a PipNet reamer and took it back to bare wood all the way to the bottom of the bowl.

I wiped down the bowl with acetone on cotton pads to remove the finish. I wanted it clean of debris and grime as well as stain so that I could do the repair. I used the dental pick to clean out the edges of the two large cut marks and the smaller chatter in the briar as well. None of them actually were fills but rather gouges in the briar. I roughened the edges and wiped it down a final time with the acetone and cotton pads.

I packed the cuts and nicks with briar dust and tamped it into place with the curved head or a pipe nail and also with the dental pick. Once they were full I dripped super glue into the grooves. I then packed more briar dust into the grooves, over filling them. I always put far more briar dust in the grooves than necessary to get good tight fills in the holes. I figure I can pack once and sand it back to the surface of the bowl instead of doing the pack two or three times. At this point in the process the photos show the pipe as a serious mess. I always wonder if I will be able to clean it up or if I had just made it a mess for nothing.

I sanded the repairs and the bowl with 220 grit sandpaper to remove the excess material on the surface of the bowl. I followed that by sanding with a medium grit sanding block. The repairs are visible in the photos below as a solid dark brown/black coloured fill.

I sanded the bowl further with medium and fine grit sanding sponges to remove the scratches in the surface of the bowl. I wet sanded with 1500-2400 grit micromesh sanding pads to smooth things out even more. I wanted the surface of the repairs to be smooth with the rest of the briar on the bowl. Once the sanding was finished I wiped the bowl down with some isopropyl alcohol on a cotton pad to clean off the dust.

I decided to give the bowl several coats of an oxblood stain that was slightly more opaque than my normal aniline stain. It is a stain that is used on kitchen cabinets and surfaces that food comes into contact with so I believe it is safe once it is dry.

I wiped the bowl down with a soft cotton cloth to remove the excess stain and then restained it a second time. I repeated the staining until the coverage was even and clear.

I worked on the stem some more with medium and fine grit sanding sponges and then with micromesh sanding pads. I wet sanded with 1500-2400 grit pads and dry sanded with 3200- 12,000 grit pads.

I rubbed the stem down with Obsidian Oil and let it soak in. I looked over the bowl again and decided to give it a top coat of a walnut brown stain. I felt that it might add some darker highlights to the repaired areas and make them less noticeable. I applied the stain, flamed it, restain and reflamed it and then buffed the bowl and the stem with White Diamond on the buffing wheel. I gave the whole pipe multiple coats of carnauba wax and then a final buff with a soft flannel buff to add a polish. The next four photos show the finished pipe. While the flaws/cuts are still visible they are no longer deep gashes in the wood. Rather they give a sense of character to the pipe and overall it is ready to go and last a long time delivering a quality smoke.

I took the final photo to give a close up view of the repaired gashes on the bowl. Though visible they are now smooth to the touch and solid and unmovable.

Learning something new while repurposing this damaged pipe bowl – adding a shank extension.

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Blog by Steve Laug

One of the pipe bowls I was recently gifted was an unsmoked Mastercraft Drysmoke bowl that had the shank cut back to half of its original length. The cutback was done poorly – crooked cut with a dull saw. It had cut right through the stamping on both sides of the shank and was crooked.

The bowl had a very heavy coat of urethane on it as well. There was some nice grain on part of the bowl but the bottom had some hack marks where it looked like the saw had jumped. I took some time to look it over and try to figure out what I was going to do with it. I was not sure and looked at the end of the cut off. I knew I would have to face the end of the shank to even things up no matter what I did with it. I could easily have just drilled the mortise large and cut a new stem for it. It would have ended up a short shank billiard and that would have been fine. However in the midst of the review I decided that it was time to learn something new. I have always wanted to learn how to do shank extensions so I figured this was a great candidate for my schooling. I flattened the end of the shank squaring it like I do when topping a bowl. I had an old vulcanite shank extension I scavenged somewhere. I had played around with it and sanded away part of the end that faced on the shank of the pipe before I threw it in my parts box. It was a mess as it was but it might just work. I also had some white Delrin tenon material that would work well. I had already turned it almost to the correct size with my Dremel and sanding drum. Maybe these parts would all come together and help me craft something different. What the heck it was worth a try and I would learn a lot in the process.

The photo above shows all the parts laid out for the connection. I faced the end of the shank using a sanding board in the same manner I used to top a bowl rim. It took a bit of work and focus to get it flattened out and perfectly horizontal. (Oh to have a lathe to do this kind of thing.) I used the Dremel with the sanding drum to fine tune the diameter of the Delrin so that it would fit well in both the end of the cut of shank and the vulcanite extension. I wanted the two parts to face smoothly against each other. I put it together to make sure I had the fit right

I put glue on the end of the tenon and pressed it into the shank and then repeated the process and pressed the extension in place. The fit against each other was exactly what I wanted. I ran some superglue in the joint between the two materials and when it dried I would sand it down. I had an old stem that had the right tenon size and inserted it to have a look. I wanted to see what the newly glued shank extension would look like with a stem in place. The joint looked good and a stick bit stem would work well when I got to that point in the process.

I removed the excess material of the extension with the Dremel and sanding drum and a lot of hand sanding with 220 grit sandpaper. I wanted to make the extension slightly flared and the transition between the shank and the extension smooth and seamless. I was going for a taper back from the bowl to the end of the shank. I also wiped the bowl down with acetone on cotton pads to remove the urethane finish. It was a tough go so I sanded the bowl and shank. I decided to not worry about sanding the partial stamping that was left on the shank as it was no longer a Mastercraft pipe at this point.

In the process of adding the Delrin I noticed that there was a crack in the shank on the right side of the pipe. It was present before I inserted the tenon, but the insert opened it up. I dripped some super glue in the crack before I put the Delrin insert in place. I knew that the insertion of the tube in the shank from the cut end to the end of the airway would give strength to the repair and also remove the pressure on the shank. I also knew that there would no more stress on the crack once the extension and tube was in place. After sanding the shank and extension I did some cosmetic work on the crack and filled it with superglue and briar dust. Once it was dry I sanded that area of the shank until it was smooth.

With the crack and repair being very visible and knowing that it would not disappear in the stain I decided to rusticate the shank and the bowl bottom. I did not worry about the visibility of the repair as the entire pipe is a repair job. I have been reading a lot about John Calich and his use of rustication and smooth finishes in the same pipe and the contrast stains to highlight the transition between finishes so I decided to try that out with this bowl. I wanted a thin band of smooth briar around the joint so I taped off the area and did the rustication with my modified Philips screwdriver. I rusticated the shank and the bottom of the bowl. I used a brass bristle tire brush to go over the rustication and knock off the rough areas. I buffed it with red Tripoli to further smooth out the rustication slightly.

I stained the bowl bottom with black aniline stain and flamed it. I repeated the staining and flaming until I had a good even coverage on the rusticated portion of the bowl. I cleaned up the smooth areas next to the stained rustication with sandpaper to remove the slight bleed from the black stain. I wiped those areas down with acetone on a cotton swab to clean the transition areas.

I found the stem I wanted to use in my can of stems. It was a slender military bit with a slight taper. I liked the look of the stem. I put it in place for the next photos. It is not stuck deeply enough into the mortise because of the taper to the end of the stem. It will need to be turned down slightly to get a good snug fit deep in the mortise.

Before going to bed last evening I rubbed down the bowl and stem with Olive oil. I wanted it to penetrate the vulcanite extension, stem and the bowl (smooth and rusticated portions) to give a bit more life to the rubber and the briar. This morning when I got up I worked on the end of the stem to get a deeper fit into the mortise. I used the PIMO tenon turning tool adjusted as small as possible and turned the first inch of the stem to get a tenon. I sanded it with 220 grit sandpaper to bring it down to the diameter of the inside of the mortise. The next two photos show the stem sanded enough to go half way into the mortise. It would take a lot more sanding before it sat against the end of the mortise.

Ah progress! Got the stem fit right – it is snug and deep in the mortise now. I sanded the tenon until it fit well. I also sanded the transition from the end of the tenon to the taper on the rest of the stem. I wanted the fit against the shank extension to be snug without the edges of the tenon showing when the stem was in place. This pipe has turned out to be a great lesson for me in the school of pipe repair up to this point. I am looking forward to “graduating” from this project at this point.

I sanded the bowl, the smooth band at the union of the extension and the briar and the vulcanite of the stem and extension with micromesh sanding pads. I wet sanded with 1500-2400 grit pads to remove any scratches in the briar and the shank extension from sanding with the fine grit sanding sponges. The photos below show the bowl and stem after I had sanded them with the early grits of micromesh. I wiped down the bowl and the stem with a cotton cloth and then rubbed Obsidian Oil into the vulcanite extension and stem.

I stained the smooth parts of the bowl and shank with a cherry stain using a cotton swab and wiped it off with a soft cloth. I hand buffed the bowl and shank with a shoe brush to give it a quick polish.

Once that was finished I continued to sand the stem with the micromesh sanding pads. I had already wet sanded the extension and the stem with the earlier grits of pad so now it was time to dry sand them with the remaining pads – 3200-12,000 grit.

When I finished sanding with the micromesh sanding pads I rubbed the vulcanite extension and stem down with Obsidian Oil and when it was dry gave the stem, extension and smooth portions of the pipe a buff with White Diamond. I gave the smooth areas of the pipe and the vulcanite multiple coats of carnauba wax. I buffed with a soft flannel buff to give it a shine. The finished pipe is shown in the photos below. It has come a long way from the cut off bowl that I started with in the beginning of this restoration. I think rather than restoring this one I have actually repurposed a bowl – a phoenix rising from the ashes. Now I have another new pipe to fire up and try out later today.

A Hilson Meerlined Tall Dublin Reborn into a Briar Calabash

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Blog by Steve Laug

I received this old briar bowl from a friend and decided to see what I could do with it. It was in pretty rough shape. The shank had been damaged and repaired with some kind of epoxy as the gel surface of the crack was hard as rock. The repair was actual the most substantial part of the bowl. The bowl had an amazing deep and craggy blast to it but the finish itself was worn. Fortunately the wear was not deep and the cragginess was not too badly affected. The rim was smooth but the edges were slightly worn. The bottom of the exterior of the bowl showed the most nicks and damage to the finish. There were marks from looked to be a band on the shank. The inside of the bowl was quite clean. Originally it looked as if it had a meerschaum lining and the glue that had held that bowl in place was gone and just a small remnant of the glue was on the interior walls of the bowl. The bottom of the bowl was stained with tobacco so evidently the meerschaum lining must have crack and seepage darkened the bottom of the bowl.

I cleaned out the inside of the bowl with cotton swabs and isopropyl alcohol. Once I had it clean I worked on the resin on the shank repair. I sanded it until it was flush with the surface of the rest of the shank so that it did not bulge. I continually checked to see if I was weakening the repair but the shank was solid. I used the dental pick and my modified Philips screwdriver rusticator to rusticate the area around the resin repair. I also found a band in my box that fit the shank perfectly and pressed it into place. The band was more for bling than as the shank was not cracked or damaged. I also went through my stem can and found a stem that fit the diameter of the shank, turned it with the PIMO tenon turning tool and fit is in place. It would need to be reduced slightly in diameter to fit well with the band. I wiped down the bowl and shank with isopropyl alcohol on a cotton pad. I did not want to chance acetone as I was worried about it dissolving the resin on the shank repair. As I did not know what was used in the repair I did not want to chance further damage.

I stained the bowl with a dark brown aniline stain. I applied it, flamed it, applied it again and flamed it again. To get an even coverage on the sandblast finish it would take more than three applications and flamings to make the stain even. The photos below show the bowl after three coats of the stain. It would need to be repeated later in the process to get the rough places stained.

I sanded the stem with 220 grit sandpaper and with a medium and fine grit sanding sponge to make the fit against the band work well. Once the shape and the fit of the stem were correct I used a heat gun to bend the stem to an angle that worked well with the look of this pipe. For the angle I used the curve of my buffer to press the softened stem over. When I had it bent I held it as it cooled and then set the bend with cool water.

After bending I resanded the stem with the sandpaper and sanding sponges. Once the majority of the scratches were gone it would need to be sanded with the micromesh sanding pads but I wanted to do some more work on the bowl and shank before finishing the stem.

I roughened the shank some more to give it a closer look to the sandblast of the bowl. I heated the bowl with the heat gun to warm up the briar before giving the bowl and shank yet another coat of the aniline stain. I gave it the fourth coat of the stain, flamed it and the coverage was finally what I was looking for on the pipe. The shank and the bowl bottom took the stain this time and matched the rest of the bowl.

I hand buffed the bowl with a shoe brush and then gave it a light buff with White Diamond on the buffing wheel. I took it back to the work table and gave it several coats of Halcyon II wax which works well on sandblast and rusticated finishes. I buffed it with the shoe brush to bring up the shine. The next three photos below show the bowl after the final stain and light buff.

At this point in the process I used a cotton swab dipped in stain to touch stain the places on the shank the underside of the bowl that were lighter than the rest of the bowl. I let it dry completely over night and then hand buffed the bowl.

In a phone call with Tim West of J.H. Lowe Pipe Repairs I discussed the possibility of making this pipe a Briar Calabash. I gave Tim the dimensions of the bowl and he happened to have a bowl that was originally made for Pioneer Calabash pipes that was the correct dimensions. He sent along several strips of cork that would be used for making a gasket to give the meerschaum cup a snug fit in the briar bowl.

I cut a strip of cork and glued it to the bowl with super glue. I used a small piece of the cork to fill the gap between the ends of the strip. Once the glue dried I sanded the cork gasket until it was the proper diameter for the briar bowl.

I used some Vaseline and lubricated the cork gasket and then used my finger to coat the inside edge of the briar bowl where the cork would sit. I then pressed the meerschaum cup into place in the briar bowl. The finished Briar Calabash pipe is shown in the photos below. The polished gloss of the white meerschaum bowl looks great against the sandblast dark brown briar bowl. The silver band gives a bit of contrast to the pipe. The draught on the pipe is perfect and the feel of the new Calabash in the hand is great. The pipe is still light in weight and the thin pencil shank and stem work well. Now all that remains is to load it up and have the inaugural smoke.

Restoring an old Bruyere Extra Chubby Billiard

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Yet another gift pipe is on the worktable. It is an interesting bowl. The exterior is carved with what looked like scales. There were several sandpits in the trails surrounding the scales. The shank had several cracks and looked as if it had previously sported a band. By appearances the band that was missing looked like it had been original rather than an addition for repairs. But the repairs were there nonetheless. The bowl was caked and the finish very dirty. It was worn away to a large degree. The fascinating part of the bowl was the drilling of the airway. The end of the mortise, which is quite large, is concave. At the end of the concave mortise there are two holes drilled looking like a colon “:”. The top hole is the airway leading into the bowl and the bottom hole is about a ½ inch deep and ends. With a stem in place the mortise looks to serve as a second chamber for cooling the smoke. The shank is stamped Bruyere over Extra in and oval with the ends flattened. There is no other stamping on the shank.

I went through my box of bands and found one that would work well on the cracked and repaired shank of the pipe. I also found a stem in my can of stems that would work well with this pipe. The tenon needed to be quite large in diameter to fit the large mortise. The stem I had was a faux Peterson stem. The airway was directly in the end of the button not on the top. Thus the look was Peterson like but the stem was actually a straight airway from tenon to button.

I added some wood glue to the area of the shank that the band would be pressed on and then heated the band and pressed it onto the shank. I reamed the bowl with a PipNet reamer to take the cake back to bare wood. I also scrubbed the rim down as it had a chamfered inner edge around the bowl.

I wiped down the bowl with acetone on cotton pads to remove the remnants of the finish and to clean up the debris and dust in the carved trails between the scales on the bowl and shank. I picked out the debris in the flaws in the trails, scratched the surface surrounding the flawed areas and then packed in briar dust with a dental pick and dripped superglue into the dust. I lightly sanded the areas of the fills and wiped the bowl down again with acetone on the cotton pads.

With the repairs completed, the band in place and the stem fitted to the shank it was time to stain the bowl. I wiped it down a final time to remove any remaining dust and debris before staining. I decided to use a dark brown aniline stain and applied it with the dauber that comes with the Feibings Shoe Dyes. The dauber works well on the wider grooves between the carved scales on the finish. I applied the stain, flamed the finish, reapplied the stain and flamed it again until the coverage of the stain was even.

I wanted a contrast to the finish – dark stain in the grooves of the trails and a bit more opaque stain on the surface of the scales so I wiped the bowl down with isopropyl alcohol to reduce the stain colour on the smooth surfaces of the finish.

I buffed the bowl with Red Tripoli and White Diamond on the buffing wheels to polish the bowl and give me an idea of the look of the finish once polished.

I sanded the smooth surfaces of the bowl with a 1500 grit micromesh sanding pad to further lighten the stain and allow the grain to pop through. The smooth surfaces had birdseye on most of them and I wanted that to stand out on the pipe.

I sanded the stem with 220 grit sandpaper to make the fit the shank even around the circumference of the saddle portion of the stem. I sanded it with medium and fine grit sanding sponges to remove the deeper scratches on the stem. I then used my normal line of micromesh sanding pads – wet sanding with 1500-2400 grit pads and dry sanding with 3200-12,000 grit pads. I also sanded the nickel band to polish it and remove the small scratches that were present in the finish.

I rubbed the stem down with Obsidian Oil and once it was dry buffed the bowl and stem with White Diamond. I gave the pipe and stem multiple coats of carnauba wax and polished it with a clean flannel buff to finish the process. The old pipe has a new look and a great feel. I look forward to giving it a try to see how the second chamber – the reverse calabash actually works on this pipe. The photos below show the finished pipe ready to use!

Giving New Life to a no-name Sandblast Apple

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I was gifted this old apple bowl. It was a nicely shaped apple with a light sandblast finish. There were some significant problems with flaws and crevices in the bowl. The major flaw was on the right side of the bowl toward the top and on the top of the rim itself. It extended into the bowl for about a ¼ inch. There was no cake or build up and the bowl seemed clean and lightly smoked if smoked at all. It had a rounded shank so it was clear that the original stem had been a stick bit of some sort – though sadly it was lost. I had it sitting in my box of pipes to be refurbed for awhile while I worked on other pipes. Its turn finally came up.

I went through my can of stems and found the kind of stick bit free hand style stem I thought would look good on this pipe.

I turned the tenon end of the stem with a PIMO tenon turning tool and then used the Dremel and sanding drum and finally some hand sanding with 220 grit sandpaper to get the stem to fit well in the mortise of the shank. With the fit nice and snug I would need to sand the saddle area and clean up the tenon to make it shine.

I cleaned up the crevices with a cotton swab and dental pick and isopropyl alcohol. I then packed some briar dust into the filled crevices and dripped super glue into the briar dust. I repeated the process until the flaws were filled and the surface of the bowl and rim bulged slightly. I sanded the rim and the fill on the side with 220 grit sandpaper to remove the excess fill. I scratched the surface with the dental pick to give it a similar texture to the surround sandblasted bowl. I sanded the saddle on the stem at the same time with 220 grit sandpaper. I finished the repair and the saddle area with a medium and a fine grit sanding sponge.

Once the area was filled and the texture finished it was time to stain the pipe. I decided to use a dark brown aniline stain that I would later wipe down with alcohol to give more transparency and aid in a contrast on the surface of the bowl. I wiped down the surface of the bowl with isopropyl alcohol before staining the bowl to remove the dust. I applied the stain and flamed the bowl and repeated the process until the coverage was even.

I wiped the bowl down with isopropyl alcohol on cotton pads to give the stain some more transparency and to lighten it.

I buffed the bowl with a light touch on the buffer using White Diamond. I took it back to the work table and hand buffed it with a shoe brush to give it a shine. There were spots on the shank and the bowl where I would need to touch up the stain as it was too light and shiny.

Once the coverage looked good I gave the bowl a coat of oxblood aniline stain to build a contrast. In the photos below you can see the way it worked to highlight the blast and show the grain. The birdseye grain under the blast on the left side of the bowl showed up with a nice contrast look.

I worked over the stem with micromesh sanding pads using the 1500-2400 grit pads to sand the surface of the bowl and give it more contrast with the crevices in the blast. I polished the stem with my usual pattern of micromesh pads – wet sanding with the 1500-2400 grit pads and dry sanding with the 3200-12,000 grit pads. I rubbed the stem down with Obsidian Oil and let it soak in. When it had dried I hand buffed the stem.

I buffed the pipe and the stem with White Diamond and then gave it multiple coats of carnauba wax. I buffed it with a clean flannel buff to raise the shine on the bowl. The finished pipe is shown in the photos below.

In closing I include two photos of the repaired areas of the bowl to show the finished repair. The super glue and briar dust repair worked well and is quite hidden by the stain and finish work. The trick was not to overfill the areas surrounding the crevice so that the filled area would blend into the texture of the bowl. I am pleased with the finished product.

Repairing a Cracked Bowl on a GBD London Made Canadian

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Blog by Steve Laug

Andrew sent me this old pipe as a bit of a challenge and I thought I would give it a go. This was a great looking pipe at one point in its life – nice grain. It is stamped GBD in the oval on the top of the shank with LONDON MADE in an arc under the oval. That leads me to believe the line is the LONDON MADE rather than the location. On the underside of the shank it is stamped: LONDON ENGLAND over D256. The 256 is the correct shape for an oval shank Canadian but I had not seen the D stamping before a number on GBD pipes.

The finish was rough and there was split in the back side of the bowl that ran horizontally in an arc across the bowl about ½ inches from the top. It was as if the grain had separated that way across the back of the bowl. It follows the arc of the grain in that part of the briar. From the main split there was a tiny crack branching off into another line of grain on the left side of the bowl. The weird thing about the split is that it was only external. There was no sign of it inside the bowl after removing the thin cake. The stem was not with the pipe so it would need to be restemmed. I found an old saddle stem in my can of stems that would work for this pipe after I modified it.

In talking on the phone with Tim West last evening while I was ordering parts for repairs I discussed this pipe with him. He said that in his estimation the crack being only on the outside of the bowl suggested that the issue was a moisture problem.

I shaped the stem with a Dremel and a sanding drum. I removed the saddle on the stem and converted it into a taper shape and also narrowed it to fit the dimensions of the oval shank. The next four photos show the newly fit stem and the rough shaping that I did with the Dremel. All that remained in the stem fit was a lot of hand sanding!

I reamed the bowl with a PipNet reamer to remove the existing cake and to check the interior walls of the bowl. They were not cracked as noted above. I washed down the pipe with acetone on cotton pads to remove the grime and the finish in preparation for doing the repair on the cracks. I picked out the debris in the cracks with a dental pick and cleaned out the sides and interior of the cracks. I washed that part of the bowl down a final time with acetone to clear away any debris left behind by my picking at it.

I packed briar dust into the cracks with a dental pick and then dripped super glue on top of the briar dust to bond it and make a fill for the crack. The next series of photos show the repair at this point from various angles.

Once the glue was dry and the patches were solid I sanded the patch with 220 grit sandpaper to smooth it out to match the surface of the bowl. I sanded it with medium and fine grit sanding sponges afterward to smooth it out further. The next photos show the initial sanding of the patches. There was still much sanding to do and some more filling in spots that were low.

I sanded the bowl and the new stem further with 220 grit sandpaper to remove the finish and smooth out the transitions. On the crack repair I wanted to even out the transition between the fill and the surrounding briar. On the new stem shank union I wanted to make that transition between the briar and the vulcanite stem seamless.

The next series of three photos show the newly sanded repair. It looks better but there are still a few areas that will need to be filled and sanded some more.

At this point in the process I was still undecided as to whether I would stain the repaired bowl or rusticate it. I posted on an online forum to see what others thought and the audience was split. I decided to stain it and see how the repair looked. If I changed my mind I could rusticate it later. I wanted to use a contrast stain on the bowl to minimize the look of the crack so I used a black aniline stain to do the undercoat. It would also highlight any areas on the repair that needed more attention. I applied the stain, flamed it and did the same again until the coverage I was looking for was achieved.

I took three photos of the repair after staining to show what the repair looked like at this point.

When the stain was dry I wiped it down with isopropyl alcohol to lighten it and bring out the grain. I wanted the black stain to settle into the grain and highlight the stripes. I wiped it down with acetone as well to further lighten the stain. I buffed the pipe with red Tripoli and White Diamond to further lighten the black undercoat. I stained it with a top coat of dark brown aniline stain, flamed and restained it for the coverage I wanted. It must be remembered at this point that this was not the finish coat but merely the way in which the repair is highlighted and makes it clear where I still need to do some work on the fills. The photos below show the repair and make it very clear where there was still work to do. This meant more filling of the crack with briar dust and superglue and more sanding. It also meant that I would need to restain that particular area of the pipe

Once the pipe was at this point several things stood out to me. I really like the grain patterns on the bowl and shank and I need to continue to work on the patch until it was well blended. So I took it to the buffer and buffed it with White Diamond and then took it back to the work table to do some more work on the patch.I sanded down the area around the repair with 220 grit sandpaper and then packed in more briar dust with the dental pick. I added more superglue until the repair was mounded slightly. While this would take more work in terms of sanding, I knew it would make the patch as perfect as possible.

Once I had the patch sanded back to match the surface of the surrounding briar with the 220 grit sandpaper, I sanded it further with medium and fine grit sanding sponges and then with 1500-2400 grit micromesh sanding pads. The scrathes left behind by the sandpapers disappeared with the micromesh sanding. I restained the area with the black undercoat, sanded it again and then gave it a topcoat of dark brown aniline stain a second time. I did not bother sanding and restaining the whole pipe as my plan was to sand the entire bowl to create the contrast I wanted with the two stains. I sanded the pipe with 1500-2400 grit micromesh sanding pads to blend in the freshly stained portion of the pipe with the rest. The next three photos show the status of the repair at this point.

I continued to sand the bowl and shank being careful around the stamping on the top and bottom of the shank with the micromesh sanding pads until the top stain was almost translucent. I wanted the top coat to be there but I wanted the grain to pop through it. I also wanted the colour to blend in such a way that the dark repair would not be hidden completely but would be minimized. The next four photos show the pipe after all of the sanding and a buff with White Diamond to enhance the shine.

I worked on the stem to remove several small tooth marks on the underside and one on the topside of the stem. I then sanded the stem with 220 grit sandpaper to further shape it and get the flow of the taper just right. I sanded it with medium and fine grit sanding sponges and then used my normal range of micromesh sanding pads to finish the work. I wet sanded with 1500-2400 grit and then dry sanded with 3200-12,000 grit pads. I rubbed the stem down with Obsidian Oil and let it soak into the vulcanite.

I did some more sanding with micromesh sanding pads on the stem to remove some of the light scratching that showed up under the flash and then buffed the stem and bowl with White Diamond. I gave them both multiple coats of carnauba wax to protect and give it a shine. The first three photos below show the repair as it stands now. The surface of the bowl is smooth to the touch. The light and the dark spots on the repair are some of the briar dust in the patchwork. Some takes the stain and is dark and there seem to always be light spots as well. This old pipe has come a long way since I received it in the mail.

The finished pipe is shown in the next series of four photos. The stem fit came out nicely. The change from a saddle to a taper style worked well. The contrast stain looks great on the pipe. Over all I am well pleased that I decided to stain it and not rusticate it. I look forward to loading up a bowl and enjoying the “new” pipe.

Giving New Life to an Old, Tired Unique

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I am not sure who the maker of this pipe original was. It has some rustication patterns that remind me of Dr. Grabow. It has a metal screw mount mortise. The flat base that extends from the bottom of the bowl backward toward the stem also has similarities to a Grabow shape. But this one is only stamped Imported Briar on the bottom of the shank. When I received it the bowl was in rough shape. The finish was gone. The stem was gone, the rim was a beaten and worn down mess. I think originally the rim was probably straight across but it was worn and beaten to the point that it was now angled. If indeed it was originally angled then the rim was badly beaten. Either way it was rough. The cake in the bowl was quite thick. The internals of the shank and airway were quite clean – that was a surprise. The briar was solid and relatively thick and sound.

As I looked at it and studied it there was something about it that drew me to the shape. The wear and tear still did not hide the fact that there was some life still left in this old pipe. I went through my can of stems and found an old screw mount stem. The stinger apparatus on it was slightly different than the old Grabows that I had seen but it would work. The draw on the stem was very constricted anyway so I figured I would end up cutting the stinger off and drilling out the metal tenon. The stem has lots of tooth marks and chatter but was solid. It was a nylon stem and not vulcanite so it was a little trickier to work with. The diameter was also slightly off and the stem was overturned once it was on the shank.

I heated the metal tenon with a heat gun until the glue softened and then turned it in the shank until it lined up. This type of tenon is actually very easy to realign.

Once the stem was aligned I reamed the bowl with a PipNet reamer and heads taking the bowl back to bare wood. I wanted to see what the shape of the bowl under the cake was like to assess whether I wanted to continue to put time into the pipe. The interior bowl was actually in excellent shape under the cake. This pipe must have been a good smoker – someone’s favourite pipe.

I set up a topping board and sanded the rim at the angle of the bowl to even out the top and to minimize the damage. The back edge was very ragged from tapping the pipe out, or using it as a hammer! It took some time to get the top flat and the angle correct from the back of the bowl to the front edge.

I wiped the bowl down with acetone on cotton pads to clean up the grime in the grooves of the rustication and to even out the remaining stain coat. There was also some varnish left on the shank that I wanted to remove.

Once the finish was gone I experimented with a metal band. The shank was not cracked or broken. It was solid but I wanted to see what the shiny silver would look like against the rugged rustication. I also wanted to minimize the slight difference in the diameter of the shank and the stem. I decided I liked the look of the band so I heated it with the heat gun and pressed it into place on the shank. I liked the finished look of the nickel band. I feel it gives a bit of bling to a rough looking pipe.

I screwed the stem in place to have a look at the fit and finish of the pipe as a whole. I thought to myself that it would work well. I would need to give the stem a bend to make a correct fit to the sitter style of the bowl but it would work.

I decided to sand out the tooth marks and chatter as much as possible. I was hoping that the heat would lift the marks a bit. I heated the stem with a heat gun to do the bending. I bent it over a rolling pin. It took awhile for the nylon to be flexible enough to bend. Bending nylon stems is far trickier than vulcanite. It does not seem to have the memory of vulcanite so once bent it remains even if heated and has to be pressed back into shape. It also kinks very easily so you have to be very careful when bending it. I have also found that the wire in a pipe cleaner heats up and the pipe cleaner can stick to the inside of the stem. All of the above make it a pain to bend this type of stem.

I finished the bend and set it with cold water. I was not happy with the overall look and flow of the stem. The bend was correct in terms of allowing the pipe to sit flat on the bottom of the bowl with the tip of the button arching to touch as well but the flow/arch of the stem was not right. I reheated and tried it a second time and still it did not quite work. I decided to stop and revisit that later.

The draught on the pipe bowl was wide open and easy but the stem itself was very constricted. The stinger apparatus had a slotted entry into the stem. It was very narrow and seemed to extend quite a distance up the stem. A pipe cleaner would not pass through the stem and the stinger. I decided to sacrifice the stinger end so I sawed it off with a hack saw and then drilled out the airway in the metal tenon. As can be seen in the photo below the drill bit went a long ways into the stem before it broke through the slotted airway. Once I had opened the airway in the stem and removed the stinger the draught on the pipe was excellent – open all the way and passing a pipe cleaner with ease.

I stained the bowl with an oxblood aniline based stain. I flamed it and restained until it was well covered. I then buffed the bowl with White Diamond on the buffing wheel. The photos below show the bowl after the staining and buffing. The colour of the briar after the stain coat was workable. The black undertones that were deep in the grooves of the rustication worked well with the red of the oxblood stain. The rim colour matched the bowl and the birdseye grain showed nicely on the flat of the rim.

The stem being nylon required all handwork. I could not use the buffer on it as it would melt and make more work than I desired to do on this pipe. Before I sanded it I used the heat gun to rebend the stem and get the angles and bend correct. Once I had that done I sanded it with 220 grit sandpaper and then with a medium and a fine grit sanding sponge. I then sanded the stem with my usual array of micromesh sanding pads – wet sanding with 1500-2400 grit pads and dry sanding with 3200-12,000 grit pads.

I rubbed the nylon down with Obsidian Oil and once it was soaked in I hand buffed it with Paragon Wax. I gave it multiple coats of the wax to preserve it. I buffed the bowl with White Diamond and then gave it multiple coats of carnauba wax with a light touch to keep the wax from building up deep in the grooves of the rustication. The next series of photos show the finished pipe. The side profile photos show the pipe in the sitter position and also from an angle. The top and bottom view photos show the new finish on the rim and the shape of the bottom of the pipe. This old worn pipe is now freshly reworked and ready to give many more years of service.