Tag Archives: restaining a bowl and rim

Operation Rescue – “My Dog Ate my Ser Jacopo L1 Billiard!”

Blog by Steve Laug

When Jeff showed me the next pipe on the table we went back and forth about buying it or just leaving it with the seller. It was a really nice Ser Jacopo L1 Billiard at some point in its life but that time had passed. It had literally become a chew toy for someone’s dog. The bowl was in very rough shape and had deep tooth gouges around the bowl with chunks of briar missing on the rim and top. The bowl was really damaged to the point of being questionable. The shank interestingly was free of bite marks and the stem had less bite marks than some of the stems I have worked on from pipemen who chew their stems. For me the question was whether or not I wanted to work on it. There was no doubt that the pipe would be a challenge but was it a challenge I wanted to take on. That was the question we weighed before moving ahead with the buy.

After spending time talking about it we decided to pick up the pipe and see what I could do with it. When Jeff got it the story became even sadder! The bowl had amazing straight grain around the sides and it appeared to have been barely smoked. It looked as if maybe a bowl or two had been enjoyed before the dog got a hold of the pipe and did the massive damage that showed when we saw it. The bowl had some darkening but there was no cake in the bowl. It smelled smoky but otherwise was very clean. Jeff would still clean up the pipe before he sent it on to me that way I would be able to just pick it up and see what I could do with it. Jeff took the following photos before he started his cleanup work on the pipe. Just look at the damage! Oh my; the pipeman or woman must have just wept after the initial shock or anger when he or she saw the pipe dangling from the dog’s mouth. He took close-up photos of the bowl and rim top from various angles to capture the gnawing damage to the bowl and rim top edges. You can see the large bite marks and chunks of briar missing on both the inner and outer edges. The largest chunk is on the front of the bowl and the inner edges damage is on the right side. You can also see the damage to the sides of the bowl. Jeff took photos of the sides and heel of the bowl to show the both the extent of the damage to the bowl and the amazing grain around the bowl. It really is a shame that this poor pipe suffered this fate. Jeff took photos of the stamping on sides of the bowl. On the left side it reads Ser Jacopo over Fatta A Mano over In Italia. On the right side it reads L1 in a circle Per Aspera Ad Aspera. On De Divina Proportione. All the stampings are very readable and clear. He took a photo of the inlays on the tapered stem top. The silver J with an I and a circle. The next two photos show the top and underside of the stem. Notice the few tooth marks on both sides. It is not as bad as it could be. I wanted to know a bit more about the pipe in hand. I knew a little of the history of the brand but I wanted to understand the stamping on the shank sides and underside so I turned first to the Pipephil website (http://www.pipephil.eu/logos/en/logo-s5.html). Interestingly the first pipe they had a photo of was similar to the one that I had. It is stamped similarly on the left side of the shank with the Ser Jacopo over Fatta a Mano but the one I have also was stamped In Italia under that. The right side of mine is stamped with the L1 in a circle and the Per Aspera Ad Astra followed that. Mine also was stamped on the underside of the shank and read: De Divina Proportione. The one I am working on also had a band on the shank and the stem stamp was different as well. I also learned the L1 stamp stood for a pipe with acceptable grain. I have included a screen capture of the pertinent information.Once I had that material digested a bit I turned to Pipedia to understand more about the stamping on the pipe (https://pipedia.org/wiki/Ser_Jacopo). I am including the information on that below. The standard nomenclature found on Ser Jacopo pipes is as follows: Ser Jacopo Fatta A Mano In Italia Per Aspera Ad Astra.

Fatta A Mano translates to “Made By Hand”. Per Aspera Ad Astra is a Latin phrase found on Ser Jacopo pipes and is the Ser Jacopo motto. It translates to “To the Stars Through Travails”, meaning that success comes through hard work. In the Summer 1997 Pipes and Tobaccos article Giancarlo Guidi translated this as “through a difficult way until the stars are reached”.

All that remained was to find out what the De Divina Proportione on the underside of the shank meant. I turned to wikipedia (https://en.wikipedia.org/wiki/Divina_proportione) for what I assumed referred to Divine Proportion or the Golden Ratio. I quote from there a good summary.

Divina proportione (15th century Italian for Divine proportion), later also called De divina proportione (converting the Italian title into a Latin one) is a book on mathematics written by Luca Pacioli and illustrated by Leonardo da Vinci, composed around 1498 in Milan and first printed in 1509.[1] Its subject was mathematical proportions (the title refers to the golden ratio) and their applications to geometry, to visual art through perspective, and to architecture. The clarity of the written material and Leonardo’s excellent diagrams helped the book to achieve an impact beyond mathematical circles, popularizing contemporary geometric concepts and images.

Now I had a clear idea of the meaning of the stamping. The Golden Ratio refers to the mathematical proportions of this particular pipe fitting that Ratio. It is seriously a beautiful pipe and now I am even sadder at the damage that was done. That motivates me to try to bring it back to some semblance of beauty.

Now it was time to look at it up close and personal. Jeff had done an amazing job in removing all debris and bits of broken briar from the finish. He had done a quick reaming of the bowl with a Savinelli Fitsall Pipe Knife. He scrubbed the exterior of the bowl with Murphy’s Oil Soap and a tooth brush to remove the grime the grime and dirt on the finish so the pipe was clean – damaged but clean. He cleaned out the interior of the bowl and shank with pipe cleaners, cotton swabs and alcohol until they came out clean. The rim top looked quite daunting with the missing chunks of briar but it too was clean. He cleaned the stem with Soft Scrub to remove the grime on the exterior and cleaned out the airway with alcohol, cotton swabs and pipe cleaners. I took some photos of the pipe as I saw it when I brought it to the work table. To show how the rim top and stem looked at this point I took a close-up photo of the rim and stem. The bowl was clean and the damage to the inner edge and the rim top was very visible. It was a mess! The black acrylic stem was saved from major dog chomping. There are just a few tooth marks on both sides of the stem that could be addressed fairly easily.I removed the stem from the bowl and took photos of the parts. I chose the left side of the bowl as really both sides were equally damaged. This is truly a sad sight to see as the great grain on the bowl shows up nicely under the damage.I had been thinking about what to do with the finish since first seeing the photos. I had decided I would rusticate it but was undecided as to what extent I would go in the process. I wanted to retain the original shape and intent of the pipe while working out the damages. I started by using three different burrs on the Dremel – a ball, a cone and cylinder. Each one gives a slightly different finish. I worked them one after another to seek to blend in the tooth marks as much as possible. I also decided to rusticate the worst areas – the base and part way up each side of the bowl and the entire bowl front. The photos show this first step. I decided to let that rustication pattern sit with me for awhile and not add more to it. I just wanted to think about it for a while. I decided then to patch the bite marks in the upper part of each side and the entire back of the bowl. I also wanted to repair as much of the rim top and edge damage as I could. I used clear super glue and briar dust to patch the many tooth marks around the bowl. The photos show the freckled sides. I built up the damaged front outer edge and the deep marks on the top of the rim with super glue and briar dust. These took some layering to do the job. I looked over the rustication some more and was not completely satisfied with the coverage of the existing rustication or the distance I came around the sides of the bowl. I decided to use a tool that a reader of rebornpipes made for me for rusticating. You can see it in the photos. It is essential a group nails bound together in a handle and with a clamp to give me multiple points to rusticate with. The way it works is to press it into the briar and twist it. You move across the briar until it is “randomly” covered. Once I was happy with the coverage I knock off the debris left behind with a brass bristly brush. I like to knock it down and smooth it out to give it an old leather like look to the rustication. I left the rustication and turned to address the damage to the rim top. I topped the rim with 220 grit sandpaper on the topping board. Once it was smoother and flatter I filled in the divots and holes in the rim top and edges with briar dust and super glue once more. Once I finished I topped it once more to smooth out the repaired areas.With that finished for the moment I turned to sanding the smooth portions of the bowl. I used my Dremel and sanding drum to flatten out the repaired areas first. I followed up by sanding them with 220 grit sandpaper. The photos below show the bowl at this point in the process. Note that there was no damage to the shank so I left it as is and would match the stain to that once I stained the repaired area. I was pretty happy with the way it was looking. I was ready to stain the undercoat on the bowl. I decided to use a black aniline stain for the rusticated part of the bowl and for the undercoat on the smooth sides and rim top. Black does a great job hiding the kind of repairs that I had to do with this briar. I applied the stain and flamed with a lighter. I repeated the process to ensure the coverage was thorough. I flamed it again and set it aside to dry while I had some dinner.I took photos of the bowl at this point to show the coverage of the black stain on the rustication and the undercoat on the smooth areas. After dinner I wiped down the smooth areas with isopropyl alcohol on a cotton pad to make them more transparent and show the grain. I then gave the smooth areas a coat of Mahogany stain using my stain pens to get into the transition areas and control the flow better. The combination of the black undercoat and the Mahogany matched the original shank colour! When that coat of stain had cured I polished the smooth portions of the bowl with micromesh sanding pads. One of the pains of this process is all the flaws show up in the initial sanding. You can see my repairs in some spots but hopefully they bill disappear a bit in the polishing. I was really happy with the right side of the bowl. The repairs virtually disappeared in the staining and sanding. I worked on the left side a little more. I sanded the offending areas of the transition with 400 grit wet dry sandpaper and restained the area. I worked through all of the micromesh pads another time on that area. I was happy with the finished looked at this point. I rubbed the finish down with Before & After Restoration Balm. I worked it into the smooth areas on the bowl and rim top with my fingertips and the rusticated areas with a horsehair shoe brush. The product cleans, protects and enlivens the briar. I let it sit for about 30 minutes and buffed it off with a cotton cloth. The photos below show the bowl at this point… it is a far cry from the dog eaten bowl that I started with — at least I think it is ;). I set the bowl aside and turned to the stem to address the issues that were on the top and underside. I filled in the tooth marks on the stem with clear super glue. I generally overfill them a bit so that it takes into account the shrinkage that occurs as the repair cures.Once the repairs had cured I sanded them smooth to start to blend them in with the surround acrylic of the stem. I sanded the repairs on both sides with a folded piece of 220 sandpaper and started polishing with 400 grit wet dry sandpaper.I rubbed the stem down with Denicare Mouthpiece Polish – a red gritty paste a lot like Tripoli to polish it after the 400 grit sandpaper. I rub it on with my fingertips and work it into the vulcanite and buff it off with a cloth. It does a great job before I polish it further with the micromesh pads.I polished the stem with micromesh sanding pads – dry sanding with 1500-12000 grit sanding pads. I wiped the stem down after each sanding pad with a cloth containing some Obsidian Oil. I finished polishing it with Before & After Pipe Stem Polish – both Fine and Extra Fine and buffed it off with a cotton cloth. The next steps in this restoration were ones that I have been looking forward to. I was glad to reunite the bowl and stem and see what the finished pipe looked like. I polished the silver with a jeweler’s cloth and buffed the bowl and the stem with Blue Diamond on the buffing wheel. I used a light touch on the rusticated portion as I did not want to fill in the rustication with the product. I gave the bowl multiple coats of Conservator’s Wax and the stem multiple coats of carnauba wax. I carefully buffed the entire pipe with a clean buffing pad to raise the shine. I finished buffing with a microfiber cloth to deepen the shine. The finished pipe looks a lot better than dog chewed pipe that I started with. I am happy with the finished look at this point. While the repairs to the smooth areas show a bit they are smooth. The leather like rustication works well with the finish on the bowl in my opinion. The finished Ser Jacopo L1 Billiard is shown in the photos below. The dimensions of the pipe are Length: 6 ½ inches, Height: 2 ¼ inches, Outside diameter of the bowl: 1 ½ inches, Chamber diameter: ¾ of an inch. This should be a great pipe once it is broken in. The rustication on the base and front give it a very tactile feel that should only be better as it heats up during a smoke. This one will go on the rebornpipes store shortly. If you are interested in it let me know. Thanks for reading this blog and my reflections on the pipe while I worked on it.

Bringing to Life a Unique Kaywoodie Natural Burl 33 – Another Legacy Pipe of a Great Grandfather

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Blog by Dal Stanton

This is the second of 3 of Paw’s pipes that Joe sent to me from Athens, Greece, where he and his wife, Hannah, live and work. Paw is Hannah’s great grandfather who left behind several pipes that Joe has asked me to restore for the family. Paw, also known as, ‘2-Page Sam’ by those who knew him as a salesman of over 40 years of the tobacco giant, Brown & Williamson Tobacco, Corp, has a fascinating story that was described in an article in B&W’s company magazine that I included in the write up of Paw’s Medico Apollo Brylon, which I just completed that turned out well (See: Another Legacy Pipe of a Great-Grandfather: Challenges Working with ‘Brylon’ on a Medico Apollo). Next, two Kaywoodies remain to be restored – a Kaywoodie “500” and the one on my worktable now, a Kaywoodie Natural Burl 33. Here are pictures to take a closer look. The nomenclature is on the underside of the shank’s smooth briar panel with ‘KAYWOODIE’ (as most of it is not legible as the upper half of ‘Kaywoodie’ bleeds into the craggy rusticated landscape) [over] ‘Natural Burl’ in fancy cursive script. To the left of the nomenclature is stamped the Kaywoodie shape number of 33. In Pipedia’s listings of Kaywoodie shape numbers, 33 is listed as: “Large apple, rounded top” that was used as a shape designator from 1937 to 1972.The dating indicators of this Kaywoodie are good. The Natural Burl has a 4-holed stinger which were phased out at the end of the 1950s, though they still show up some in the 60s according to Pipephil.eu’s discussion about Kaywoodie’s stinger evolution. The inlaid white shamrock also points to an earlier period.I found nothing specific in Pipedia or Pipephil.eu about Kaywoodie’s ‘Natural Burl’ line. Expanding my search, I did find very helpful anecdotal information in a February, 2013, thread by ‘kwguy’ on a Kaywoodie discussion group on Tapatalk.com:

Natural Burls are in the catalogs from 1957 to 1962. They were $4.00 when they first came out and $5.00 by the time they were discontinued. They were basically a stained version of the Coral White Briar, which also debuted in 1957. The overall rough texture was described in the catalogs as having a rough texture like the outside of the burl. The rough texture in theory would create more surface area for a cooler feeling bowl. Carving of this type was done on bowls of less desirable grain and with excessive surface imperfections. On the lower side of the quality scale, Natural Burls would have had the white cloverleaf. There may have been the occasional higher grade pipe that was downgraded during production and hence would have the round logo, but I think you’ll mostly see them with the white logos.

Based upon the information of this thread, the Natural Burl Apple before me dates from 1957 to 1962, when they were featured in Kaywoodie catalogs. I looked for a catalog during this period online, but unfortunately, I was unable to find one. The rusticated or carved surface theoretically provides a cooler feeling bowl. This pipe fits Sam’s low budget approach to his pipes. When the Natural Burl Apple first hit the market, it was in a working man’s modest budget range, $4! I’m hopeful that after I’ve completed working on Paw’s vintage Kaywoodie it will look like a million bucks!

The above thread from ‘kwguy’ also mentions that the ‘Natural Burl’ line was featured in Kaywoodie catalogs from 1957 to 1962. There are Kaywoodie catalogs and adds referenced on Pipedia and the Chris Keene Directory of Pictures, but I could find nothing in these ‘go-to’ places for catalogs or listing between 57 and 62. Emails to Steve and rebornpipes contributor, Al Jones, also came up empty. However, Al encouraged me to reach out to Bill Feuerbach, the current president of S.M. Frank with Kaywoodie production in New York. Al said that Bill had always been helpful and had seemed to enjoy providing info. Nothing like going to the top of the pipe food chain! I sent a note to Bill through the S.M. Frank website as well as to the ‘kwguy’ in the Natural Burl thread with the hope of getting a response and perhaps a historical Natural Burl add!

Al’s suggestion to me paid off! In a few days I received a response from Bill Feuerbach, president of S.M. Frank since taking over the role from his father in 1990 as the fourth generation of Feuerbachs overseeing the company. Bill’s note to me:

Dal

I’d love to be able to help you out with that. I’ve looked through what I have at the shop and most of those catalogs are later 60’s to later 70’s. I’m sure I’ll have those older catalogs from that range at home. I’ll try and check tonight.

Best regards

Bill

After arriving home that night, Bill sent an additional note that he hadn’t found anything at his home and would redouble his efforts the following day at the shop to find the sought after ’57 to 62’ catalog pages. Then, this note came in and the treasure hunt ended with success!

Dal

Success!! I found the catalogs at home. They were in a storage tub in the downstairs closet. Funny I don’t remember putting them there. It’s probably been 4 years since I referenced them. It is hell getting old, CRS is kicking in.

Anyway, I’ve attached three images from the 1958, 1960 and 1962 catalogs. I was only using my phone to take pictures and it was difficult not to get any flash or glare. Are they ok? You can tell the year by the retail prices for the Natural Burl.

1958- $4.00

1960- $5.00

1962- $5.95

Let me know when you’ve posted this and the link. I’d like to take a look. If you have any other questions let me know. If in the future you need other images from the catalogs, let me know.

Best regards

Bill

The images Bill sent were great depicting the Kaywoodie presentation of the Natural Burl line. Both the 1960 and 1962 pages, second and third below, showcase the Large Apple on my worktable. The pictures and descriptions are great helping to wrap Paw’s pipe in its historical context! I appreciated the help of Bill Feuerbach, president of the S. M. Frank Co. & Inc. based in New Windsor, New York. The Frank website not only showcases the Kaywoodie, Yello-Bole and Medico brand lines, but has other interesting information as well. In my email response to Bill, I offered to digitize the ‘treasure tubs’ of Kaywoodie catalogs and adds if I only lived a bit closer to his neighborhood! Oh my….

As I was waiting for word from Bill before he found the catalogs, I reread the Pipedia article on the S.M Frank Co. and discovered at the bottom of the article a reference to Brian Levine’s interview of Bill on the Pipes Magazine Radio Show. I tuned in to learn more about Bill and the Kaywoodie name. I was interested to hear in the interview that not only is Bill the CEO of the company, but he is an accomplished freehand pipe maker himself, likes single malts and owns and enjoys pipes in his rotation other than Kaywoodies! It was a great interview and I encourage readers to tune in too!

The name for this Kaywoodie series, ‘Natural Burl’, harkens back to a pipe’s origins – or at least its bowl. The Natural Burl adds above from Bill describe the ‘rugged, weather-carved briar’ that breathes more because of the increased surface of the bowl. Briar comes from a bush-like plant that grows in arid lands. The Kaywoodie motif focuses on the rough state of the burl in its natural form sporting rusticated or carved bowls to emulate a natural harvested burl. The burl is the base of the briar bush that is cut into blocks, each becoming the raw material for fashioning each unique bowl. I found this example online of the burl texture which looks very much like the pipe on my worktable! This interesting information was added about the process at the WorthPoint site:

The mother of briar is Erica Arborea, an evergreen bush / tree, that grows in all forests of the Mediterranean area, preferring acid soils (Cyprus, Greece, Italy, Spain, France, Portugal, Morocco, Algeria- these are the countries where it is found). The bush has a typical height of 3 – 12 feet. But not the visible parts are the wanted ones, the ball-like roots are the pipe makers desire. These are the raw material for the briar wood, which is cut in blocks (plateaux and ebauchons) by real specialists. After a long process of boiling them in clear water and drying periods, these briar blocks will be ready for the experienced hands of a pipe maker.

With a deepened understanding and appreciation for Paw’s Kaywoodie on my worktable, I look more closely at the issues it brings from its years of service. As one would expect, the craggy Burl bowl is full of grime. The chamber has thickening cake as you go down toward the floor. This needs to be cleaned out as well to inspect the chamber wall and to give the briar a fresh start. The rim has evidences of Sam’s penchant for knocking the stummel on the back side of the rim. It is worn and tapers away from the chamber. The rim was fashioned to be somewhat rough complementing the craggy bowl motif, but there is a large chip or divot out of the rim that will need to be filled and then blended. The bowl itself, along with the rim, is faded and skinned up. I suspect that the original finish bent toward a light brown, but it is now thin and will need refreshing with new dye to blend the rim and bowl. The 1962 add above describes a ‘2-tone brown finish’ characterizing the ‘Natural Burl’ line. This is helpful information that hints at the depth of the final finish.The stem is in rough shape. The oxidation is thick and deep. The bit has calcium caked on it and some lower tooth compressions – not as bad as I’ve seen on Paw’s previous pipes! The stem orientation is also over-clocked which is a normal phenomenon with Kaywoodie screw in stems that happens over years of use with repeated loosening and tightening. This will need to be adjusted as well. I begin the restoration of Paw’s Kaywoodie Natural Burl Large Apple by addressing the severe oxidation in the stem. Before placing the stem in a soak of Before & After Deoxidizer, I get a head-start on removing the oxidation by pre-sanding the stem. I use both 240 grade sanding paper and 000 grade steel wool to sand the stem to remove as much oxidation and caked calcium as possible. The nickel 4-hole stinger also is cleaned up with the steel wool.After the sanding, the stem joins other pipes in the queue in a soak of Before & After Deoxidizer. After a few hours, the Kaywoodie’s stem is extracted from the Deoxidizer and after draining, I squeegee the liquid off the stem with my fingers. I then run a pipe cleaner wetted with isopropyl 95% through the airway to clear the Deoxidizer. Using a cotton pad and alcohol, the stem is wiped to remove the raised oxidation resulting from the soak.After cleaning the stem, paraffin oil is applied to help condition the vulcanite. I put the stem aside to absorb the oil. The stem looks great compared to where it started. It’s cleaning up nicely.Next, I turn the attention to the stummel. I begin by reaming the Kaywoodie’s chamber to remove the cake. Using the Pipnet Reaming Kit, I use two of the four blade heads available in the Kit. I don’t know how long this cake has been waiting to be removed, but it is as hard as a brick. I’m careful not to force the blades beyond their torque endurance level – simply allowing the scraping action to wear away the brick cake. When both blades do what they can, the Savinelli Fitsall Tool continues the scraping of the chamber walls. Finally, to remove the last remaining carbon remnants, a 240 grade sanding paper is wrapped around a Sharpie Pen to sand the chamber getting down to fresh briar. After wiping the chamber with a cotton pad wetted with alcohol, and inspection reveals a perfectly healthy chamber. The picture on the 10^th floor Man Cave balcony where I’m working, does not allow a very good picture of the chamber, but it looks good. Moving on.Next, using undiluted Murphy’s Oil Soap, I go to work on the wonderfully craggy but grime-filled surface of the Natural Burl bowl. I use a cotton pad a bit, but transfer to using a bristled toothbrush which gets into the nooks and crannies of the landscape much more effectively.Next, after transferring the bowl to the kitchen sink, I continue to clean the surface and use shank brushes and liquid anti-oil dish soap and warm water to work on the internals. After rinsing thoroughly, back on the worktable I take some pictures of the results. The cleaning has totally removed what was left of the old finish – not unexpected. The cleaning reveals some white fills on the right side of the stummel which are fully embraced in the craggy landscape cover and seem to be solid after testing them with a sharp dental probe.Next, I focus again on the internal cleaning using pipe cleaners and cotton buds wetted with isopropyl 95%. Cleaning Kaywoodie pipes tends not to be easy. Working through the threaded metal shank facing makes access to the mortise difficult. Along with pipe cleaners and buds, the full arsenal added the use of shank brushes, and a dental spoon to scrape the mortise walls. After quite a bit of time and effort, the buds start to emerge lighter and a cease fire is called. I’ll continue the cleaning later with a kosher salt and alcohol soak to work through the night to further clean and freshen the internals of the Kaywoodie stummel.Turning now to the rim, the next step is to fill the divot, or perhaps, the crater on the rim. I go along with the ‘rough’ motif of this Kaywoodie Natural Burl. The rim is rough and the only repair I plan for the stummel is this divot. The damage of Paw’s knocking will remain – it simply adds to the rough rustic look and will be a remembrance of Paw when it is put into service by the family.I place a small mound of briar dust on the mixing palette that I’ve covered with scotch tape for ease of cleaning. Next to the briar dust a small amount of BCI Extra Thick CA glue is puddled.Using the toothpick, briar dust is pulled into the glue and mixed as it is added. As more is added, the resulting briar dust putty thickens. When it reaches the thickness of molasses, with the toothpick the putty is troweled to fill the rim divot.With the briar putty applied, I place the stummel aside for several hours for the putty to cure.Turning now to the stem, the upper bit is in good shape after the ‘pre-sanding’ that was done before putting the stem into the Deoxidizer. The lower bit, pictured below, has some compressions and a button bite compression that need addressing.I start by using the heating method with a Bic lighter. Using the flame of a Bic lighter, I paint the bit using a back and forth motion heating the vulcanite. As the vulcanite heats, it also expands to regain the disposition of the stem before the compressions were made by Paw. The picture below is after the heating and the process has helped the bit compressions so that only sanding should be needed to remove the damage. However, the button is still in need of additional steps.To fill the button lip bite, after wiping the area with alcohol to clean it, I spot drop black CA glue on the compression and put the stem aside for the patch to cure.The patch on the rim is now ready for filing. I use both the flat and half-rounded needle files to remove the excess putty and to shape the internal curve of the rim. I put a stop on sanding and further cleaning the rim because the hour is late, and through the night I want to use a kosher salt and alcohol soak to advance the cleaning of the internals of the stummel. I first fashion a cotton ball into a ‘wick’ by pulling and twisting it. It is then inserted down the mortise into the airway with the help of a stiff wire. The wick helps to draw out the latent residue of tars and oils.The bowl is then filled with kosher salt, which leaves no aftertaste as with regular iodized salt. After placing it in the egg carton to keep it stable, I then fill the chamber with isopropyl 95% until it surfaces over the salt. After a few minutes, as the alcohol is drawn into the stummel, the alcohol is topped off and it is set aside to work through the night. The next morning, the salt and wick are slightly soiled which hopefully means that the internals are already clean from earlier. After dumping the expended salt and wiping the bowl with a paper towel, I blow through the mortise to make sure all the salt crystals have been dislodged. To make sure that the internals are clean, and nothing has been left behind after the soak, I use only one pipe cleaner and cotton bud as confirmation of the cleaning. Moving on.I return now to the rim. I plan to apply a fresh color to the stummel and the only preparation for applying the new stain to the stummel is on the rim. I plan to leave it in the rough motif of the Natural Burl line, but I want the rim cleaned. I lightly sand the internal rim edge as well as lightly around the rough external rim edge as it transitions into the Burl landscape. I’m looking for ‘rough’ and ‘rustic’ but ‘fresh’ to give this unique Kaywoodie a fresh start.I follow the 240 paper with 600 grade paper with the same approach – keep the rustic but refresh the rim.Before moving to the next step, I notice that the nickel shank facing after the cleaning had not been spruced up. A quick revolution of 000 steel wool takes care of this. This is the only bling this Kaywoodie has and I’m making the most of it!As I think about applying a fresh color to Paw’s Kaywoodie, I have only one picture of another Natural Burl online and it is no help in hinting at the original 2-toned brown coloring Kaywoodie used. The best clue I have is on Paw’s pipe. The smooth briar panel on the underside of the shank holding the nomenclature holds a clue. To guard the stamping on the panel I’ve not sanded it – only cleaned with the rest of the stummel. I’m guessing that the coloring of the panel leans toward a light brown. I’m thinking that Kaywoodie’s approach was straightforward with this less expensive line of pipes. Yet, the craggy surface now is so dry and bare, showing pristine briar, that applying even a light brown dye will probably darken considerably as the thirsty briar drinks it in.Looking at the craggy landscape in the picture above brings the next question in my mind about applying a new finish. My normal way of staining with aniline dye is to flame it to combust the alcohol which encourages a deeper embrace of the dye by the briar grain. My normal follow-up to this is then to apply compounds to remove the crusting the combustion creates and to further shine the surface with the fine abrasives of Tripoli and Blue Diamond compounds. The roughness of this stummel causes me to question my normal approach. My concern is that if compounds are used on this craggy rough surface, I will forever be trying to clean out the compound residue lodged in the rough surface! I think I can utilize buffing wheels on the Dremel without too much problem, but without compounds. I decide in the end to apply a dye wash instead of flaming the dye because of this concern.

After wiping the stummel down with a cloth and alcohol to clean it the best I could, the stummel is heated with the hot air gun to open the briar.Then, with the use of a folded pipe cleaner, the surface is painted with Fiebing’s Light Brown Leather Dye. I make sure the dye is getting into all the cracks, crevasses, nooks and crannies. The rim also receives the dye.After the dye is applied, the stummel is set aside to rest for several hours before continuing with the next steps of finishing. This ‘rest’ helps the new dye to stabilize in the briar.Turning back to the stem, the patch applied to the lower button lip is cured and I use a flat needle file to remove the excess patch material and to shape and refresh the button lip. I also file the bit area to remove any residual tooth compression.Flipping over to the upper bit, I file residual compressions as well as refresh the button lip. Refreshing the button lip is helpful to allow a better ‘hang’ grip of the pipe without biting and clenching, and extreme chewing!Continuing now with 240 grade sanding paper on the upper side, the file scratches are removed, and the button is smoothed further. The same is done on the lower bit and to further blend the button patch. I expand the 240 sanding to the entire stem to make sure that residual oxidation has been addressed. Following the 240 sanding, I wet sand the entire stem with 600 grade paper and follow with applying 000 steel wool. The nickel stinger is also a benefactor of the steel wool polishing again.Moving on, the full regimen of 9 micromesh pads are applied by first wet sanding with pads 1500 to 2400 and dry sanding with pads 3200 to 4000 and 6000 to 12000. Between each set of 3 pads, Obsidian Oil is applied to condition the vulcanite and to guard against oxidation. I love the glossy pop of newly micromeshed vulcanite! I had observed earlier that the Kaywoodie screw in stem was over clocked a few degrees. This happens over time with tightening and loosening.To correct this problem and to bring the stem back to an accurate orientation, a Bic lighter is used to heat the nickel 4-hole stinger. Since the stinger is gripped by the vulcanite of the stem, the goal is to warm the stinger so that the vulcanite gripping the stinger heats and loosens its grip allowing the stinger to rotate. After heating the stinger, I quickly re-screw the stem into the threaded shank facing and when it tightens to the orientation pictured above, I continue to apply clockwise pressure and the heated vulcanite releases its grip and it allows me to turn the stem one full revolution to line it up correctly. I had to heat the stinger twice as the first try did not loosen the grip. After lining the stem orientation correctly, I leave the stem in place and as the vulcanite cools, the grip on the stinger is re-engaged holding the stem again in the proper orientation.Time to address the dyed stummel. It has been resting for several hours to help stabilize the dye in the briar.I use a cotton pad wetted with alcohol to wipe down the dyed stummel. I do this to remove excesses of dye on the surface and to lighten and blend the new dye.Next, I mount a cotton cloth buffing wheel onto the Dremel and simply buff the stummel. I do not use any compounds so that the compound dust does not fowl up the surface getting lodged in the plethora of hiding places on the Burl surface causing me to have to clean it! The Dremel is a great tool for getting into the nooks and crannies of the Natural Burl landscape. I’m able to rotate and move up and down ridges and to reach into crevasses. The newly dyed surface responds well to the buffing wheel. The coloring of the wheel shows that new dye is leeching out of the surface. The more I’m able to remove now, less likely to come off on hands later!Next, I use the 1500 grade micromesh pad and lightly sand over the Burl surface. The aim is to ‘scalp’ the peaks of the mountain tops on the craggy surface to lighten them. The lightening of the peaks creates more contrast and depth definition to the landscape. I follow the scalp sanding by running the Dremel’s buffing wheel over the surface again. This, I believe, achieves the ‘2-toned’ look of Kaywoodie’s design for the ‘Natural Burl’ line.In the homestretch – next, I mount another buffing wheel onto the Dremel setting the speed at about 40% full power. After reuniting the Kaywoodie’s stem and stummel, Blue Diamond compound is applied to the rim and smooth briar surface on the underside and end of the shank. The compound is also applied to the stem. After applying the Blue Diamond compound, the pipe is buffed with a felt cloth to remove the compound dust from the areas on the stummel and from the stem. Next, another cotton cloth buffing wheel is mounted and set at the same speed and carnauba wax is applied to the entire pipe. I’m careful to apply with a very light touch of wax to the Natural Burl surface not to allow wax to build up in the crannies. Wax is applied to both stummel and stem and then the pipe receives a rigorous hand buffing with a microfiber cloth to raise the shine.

Wow! I’m very pleased with how this Kaywoodie Natural Burl Apple shaped up. The brown craggy finish is flecked with shade differences that give it a depth and warmth – a rustic knobby feel. I always enjoy the contrast nuances that the coalescing of rough and smooth briar creates. The smooth briar underside and shank ring alongside of the Burl texture is nice. I’m amazed that this pipe occupied the lower shelf on Kaywoodie’s offerings back in the day when Sam chose it and added it to his rotation of pipes. The TLC it has received has enhanced the briar presentation with this unique Natural Burl finish. I appreciate the collaborative help from Bill Feurbach who even as the president of the S.M. Frank Co., was not hindered from helping with the recommissioning of this one vintage Kaywoodie – a pipe man at heart. Thanks, Bill! I like the Natural Burl a lot and I trust that Joe likes it too. Paw’s Kaywoodie Natural Burl 33 – Large Apple, that was put into production in the mid-50s/early 60s, is a venerable 60-year-old(!), and is starting a new lifetime in the loving care and stewardship of Paw’s family. Adding frosting to the Kaywoodie cake, Joe’s commissioning of this restoration of Paw’s Natural Burl also benefits the Daughters of Bulgaria – women and girls who have been trafficked and sexually exploited. Thanks for joining me!

New Life for a Second Generation Butz-Choquin A Metz Origine

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Blog by Steve Laug

The next pipe on my worktable brings back a lot of fond memories for me. The first is walking through the restoration of Paresh’s Grandfather’s A Metz Origine. Paresh and I had chatted on Facetime many times during this particular restoration (https://rebornpipes.com/2018/11/17/a-challenging-restoration-of-vintage-era-first-choquin-a-metz/). Paresh had determined that this pipe was very old. I quote:

From all the input that I have gathered, the flat bottom bowl, the stamping, the sterling silver adornments, the bone shank extension and horn stem, I can safely place this piece as being one of the first A Metz pipes from the 1858 era! (Photo from Paresh)That was the first memory of the Origine. The second one is also is one I cherish. On my trip to India last year to visit Paresh and Abha and their daughters Mudra and Pavni I had the privilege of not only seeing this pipe up close but of also being the first one to smoke it since the restoration. What a privilege to be able to smoke Paresh’s Granfather’s pipe. It was so light weight and an amazing smoke. It was cool and dry to the end of the bowl. I cannot thank Paresh enough for letting me fire up this old timer. Dal wrote about this in a great blog about the trip called West meets East in India (https://rebornpipes.com/2019/05/30/west-meets-east-in-india-to-restore-a-grandsons-treasure-an-1846-bbb/). I quote Dal as he so ably described this experience:

As we had planned, in celebration of the completion of the restoration together we smoked 3 unbelievable vintage pipes with albatross shank extensions and horn stems – all from the 1800s. Oh my…. We each thoughtfully packed our bowls with our choice of blends and lit up and, well…. What a treat for Paresh to share the treasure trove of pipes left to him by his grandfather. Jeff did the honor of commemorating this event with pictures. (Photo from Dal)For me smoking that older BC A Metz Origine was a delight. I was able to enjoy a great English tobacco in this historic pipe. So when this pipe showed up in one of Jeff’s auctions we went for it and picked it up. While the 1858 Origine had an albatross wing bone for the shank extension the new one had a shorter acrylic look alike. The shape of the bowl is the same but the 1858 version’s horn stem was replaced by an acrylic stem that was nowhere near as elegant as the first.The pipe was in overall good condition. The silver (polished nickel) that caps the shank and the faux “bone” extension was tarnished but in good condition. The stem was amazingly clean with just some tooth chatter on both sides near the stem. The finish was dull and lifeless and a little dirty from sitting around. There is a cake in the bowl and an overflow of lava on the rim top toward the back. There also appears to be some burn/charring damage on the inner edge in the same area. The pipe is stamped on the left side of the shank and reads Butz-Choquin over A Metz over Origine. On the right side of the shank it is stamped St. Claude France over the number 2. Jeff took the previous and the following photos before he started his cleanup work on the pipe.Jeff took close-up photos of the bowl and rim top from various angles to capture the condition of the bowl and rim top edges. You can see the darkening around the inner edge of the rim and the damage at the back of the bowl. You can also see the cake in the bowl and the lava overflow onto the back of the rim top. He took photos of the sides and heel of the bowl to show condition of the briar. You can see the birdseye grain on sides of the bowl. And the cross grain on the heel, front and back of the bowl. The stamping is very clear on both sides of the pipe. The next two photos confirm what I wrote about the stamping above.The next photo of the stem to shows the general condition of the stem. The flow of the shank extension with a silver cap each side is well done. The angle of the stem is very similar to the shape of the original 1858 horn stem. Jeff took photos of the top and underside of the stem to show the light tooth chatter on both sides near the button. I turned to Pipephil (www.pipephil.eu/logos/en/logo-butzchoquin.html) to get a bit of background on the second or the modern version of the Origine pipe. I have included a screen capture of the pertinent section below.Now it was time to look at it up close and personal. Jeff had great job in cleaning up this Origine. He had reamed the bowl with a PipNet Pipe Reamer and cleaned up the remnants with a Savinelli Fitsall Pipe Knife. He took the cake back to bare briar so we could check the walls for damage and also see the extent of the burn damage on the back of the inner edge of the rim. He scrubbed the exterior of the bowl with Murphy’s Oil Soap and a tooth brush to remove the grime on the bowl and rim and was able to remove much of the grime and dirt. He cleaned out the interior of the bowl and shank with pipe cleaners, cotton swabs and alcohol until they came out clean. The rim top looked much better when you compare it with where it started. The damaged area is very clear now and the extent of the damage was clear. He cleaned the stem with Soft Scrub to remove the grime on the exterior and cleaned out the airway with alcohol, cotton swabs and pipe cleaners. I took some photos of the pipe as I saw it. To show how clean the rim top and stem really was I took a close-up photo of the rim and stem. The bowl was clean and cake free. The rim top is quite clean and the damage to the back inner edge of the bowl is clear. The pinkish/bone coloured acrylic stem looks very good. The surface and the button edge look really good. There are no issues that are there to address. The tarnished silver ends on the shank ends have a rich shine to it now as well.I removed the stem from the bowl and took photos of the parts. The shank extension came apart at the shank end but not at the stem. It was glued to the stem and unmovable. The pipe looks pretty amazing – kind of a shorter version of the 1858 Origine.I decided to address the burned area on the inner edge and top of the rim first. I started by lightly topping the bowl to clean up the top edge. Once it was smooth I used a folded piece of 220 grit sandpaper to give the inner edge a bevel to minimize the damage at the back of the bowl. I decided to polish the rim top and the bowl next. I polished them with the micromesh sanding pads – wet sanding with 1500-12000 grit pads to remove the sanding scratches on the rim top and blend it into the bowl. I wiped it down with a damp cloth to remove the sanding dust. When I finished the bowl and rim top looked significantly better. I touched up the stain on the rim top Oak stain pen. The match to the rest of the bowl was very good. Once I buffed it the colour would be a perfect match. The repaired rim top looked very good and the burn damage was gone.I rubbed the bowl and shank down with Before & After Restoration Balm to deep clean the finish on the bowl and shank. The product works to clean, enliven and protect the briar. I worked it in with my fingers to get it into the briar. I let it sit for 10 minutes to let it do its magic. I buffed it with a soft cloth. The briar really began to have a rich shine. I took some photos of the bowl at this point to mark the progress in the restoration. It is a beautiful bowl. The bowl was finished so I set it aside and turned my attention to the stem. Since it was quite clean I decided to polish the stem and shank extension with micromesh sanding pads – dry sanding with 1500-12000 grit sanding pads. I wiped the stem down after each sanding pad with a cloth containing some Obsidian Oil. I finished polishing it with Before & After Pipe Stem Polish – both Fine and Extra Fine and buffed it off with a cotton cloth. I put the bowl and stem back together again and buffed it with Blue Diamond on the buffing wheel. I used a soft touch on the extension and stem but work the bowl over with a regular touch to the wheel. I buffed the pipe with carnauba wax and a clean buffing pad to raise the shine. I finished buffing with a microfiber cloth to deepen the shine. The grain patterns came alive with the buffing and wax and looked great to me. It has a great feel in the hand and if it is at like the first generation 1858 Origine should smoke very well. The finished Butz-Choquin Origine 2 pipe is shown in the photos below. The dimensions of the pipe are Length: 8 ½ inches, Height: 2 inches, Outside diameter of the bowl: 1 ¼ inches, Chamber diameter: 5/8 of an inch. This modern replica of the original A Metz turned out very well. It should be a great pipe. It is one that I am not sure what to do with at the moment. It brings back the memories spoken of at the beginning of the blog and I need to sort that out a bit before making a decision. Thanks for reading this blog and my reflections on the pipe while I worked on it.

Another Legacy Pipe of a Great-Grandfather: Challenges Working with ‘Brylon’ on a Medico Apollo

1 Reply

Blog by Dal Stanton

It gave me a great sense of satisfaction when I received Joe’s response to reading and seeing the results of restoring the first of Paw’s pipes entrusted to me. Joe and his wife, Hannah, who live in Athens, Greece, and are colleagues working in our organization, last year sent me a Kaywoodie “500” that I restored (See Link: Reclaiming Paw’s Kaywoodie “500” 04 Long Stem Billiard – A Great-Grandfather’s Legacy) as a gift for Hannah’s father, Ben, ‘Paw’s’ grandson. The Kaywoodie was a special gift for Ben’s birthday. Later, Joe wrote this letter:

Hello Dal,

My in-laws came to Athens to visit Hannah and I last month. I gave Ben the pipe. I showed him everything you wrote and documented about it. He absolutely LOVED how the pipe looked, and he was also deeply touched by the love, care, and respect you showed not just the pipe but his family.

So many things you said in your blog triggered sentimental images for Ben about his grandfather, Sam Ellison. You called Sam (AKA Paw) a “knocker” and explained that based on some of the inner rim damage, that was from when Sam would knock out residual tobacco from the bowl, and Ben immediately could remember and visualize Sam doing that.

During Ben’s last few days in Athens, he lived in blissful nostalgia, thinking of Paw and sweet memories along with him. When Ben went back to Georgia, he went through the storage unit and found stacks of old pictures and articles. Unfortunately, he couldn’t find a picture of him smoking the pipe, but there are some pictures (that I will attach below) of Paw with some of his tobacco co-workers at Brown & Williamson Tobacco Corp, along with an article in the Brown & Williamson newsletter, “The Pipeline” about him called ‘Two page Sam’.

Two pictures Joe included were of Ben, his father-in-law fellowshipping with Paw’s newly restored Kaywoodie “500” and reminiscing about his grandfather. What I understood from Joe, was that Paw essentially was the one who raised Ben. The other picture was Paw and Ben 45 years earlier…. This is why I love what I call my work, The Pipe Steward – pipes are passed on, but also the special memories those pipes uniquely bring with them are also passed on to the following generations.

What was also of great interest to me in Joe’s letter, not only was Paw a pipe man, but he was also a tobacco man – not just a tobacco man, but a tobacco SALES man for the Brown & Williamson Tobacco, Corp. and sent clips of an article of this tobacco company’s magazine about Paw, or as the rest of the world new him, ‘Two-Page Sam’! When doing a restoration (and I will get to that!) it doesn’t get better than this regarding the story a pipe tells. Doing a little research, I find out that B&W would be considered a ‘Big Tobacco’ company and Wikipedia described the beginnings in the latter 1800s:

B&W was founded in Winston (today’s Winston-Salem), North Carolina, as a partnership of George T. Brown and his brother-in-law Robert Lynn Williamson, whose father was already operating two chewing tobacco manufacturing facilities.^[3] Initially, the new partnership took over one of the elder Williamson’s factories.^[4] In February 1894, the new company, calling itself Brown & Williamson, hired 30 workers and began manufacturing in a leased facility.

In 1927, the Brown and Williamson families sold the business to London-based British American Tobacco. The business was reorganized as the Brown & Williamson Tobacco Corporation. Manufacturing and distribution were expanded, and work on a new B&W factory in Louisville was begun.

The Wiki article jumps a century from this earlier history to the 1990s which was a time rife with controversy regarding infamous ‘Big Tobacco’, congressional hearings, cover-ups and 60-Minutes TV pop-journalistic investigations – all low-hanging ripe story lines for a John Grisham novel and movie contracts! As tantalizing as this later storyline was, I was drawn more to the story of ‘Two-Page Sam’, the article written about Paw’s life and relationships through the years that the Wiki article jumped over. I include this story from the December 1984 article that Joe sent from B&W’s company magazine, ‘PIPELINE’. The piece was subbed: “’Two-Page Sam’ – An 81-year old retiree, with a memory like a steel trap, about his 43-year career with B&W”. I enjoyed the read immensely as it not only tells of the life of Paw – aka, Two-Page Sam, but its portrayal of period perspectives revealing much about life and relationships when Sam started work for B&W in 1923 and later. Enjoy! After the test run with Paw’s first pipe, Joe entrusted me with three more pipes to restore – two more Kaywoodies and a Medico. Paw’s choice of pipes tells much about him! One of the Kaywoodies is another of the “500” series, but this time, in addition to the long-shank Billiard from last time, a “500” Rhodesian is added. Paw liked the “500”s – they are smaller pipes easier for hands-free fellowship (and chewed bits!) and work, as Sam went from vendor to vendor in his job selling tobaccos. The other Kaywoodie is a Kaywoodie Natural Burl 33 – the finish is great! Here is the lineup of Sam’s pipes that Joe sent:Along with the other Kaywoodie “500” its obvious that Sam stayed with American made pipes – pipes that would be considered ‘working men’s pipes’. They are not high shelf purchases but would be found on many of the shelves of the tobacconists and ‘mom & pop’ stores he served through the years. Affordable pipes that would be the kind a person who had known life through the Great Depression and Great Wars – as a child then as an adult – often called, the Great Generation. With a deepening understanding of the man who was a steward of these pipes, I’m appreciative of the trust that Joe (and Hannah!) has placed in me to restore them as treasured family heirlooms. What’s even better is that these restorations benefit the Daughters of Bulgaria – women and girls who have been trafficked and sexually exploited.

After looking over the pipes, I decided to start with the Medico Apollo Brylon – the most challenging. With the Medico now on the worktable I take some pictures to get a closer look. The nomenclature found on left shank flank reads MEDICO [over] Apollo [over] Brylon (with circled ‘R’ for registered trademark). The stem has a fancy, lopsided (or worn away) ‘A’ for Apollo pressed into the right side.During my communications with Joe about the conditions of the pipes he intended to send to me, I was assuming that this Medico was a briar that had dulled. It wasn’t until I received the pipe and started to research the Apollo ‘Brylon’ line of Medico that I discovered the stummel was not made of briar but ‘Brylon’. Pipephil.eu confirmed another Medico Apollo Brylon and the stem stamping but with no further information about the ‘line’ Brylon.Pipedia’s short introduction to the article about Medico provides this:

Medico was created in 1933, and is still produced by S.M. Frank. The brand is famous for its pipe filters, which were launched in the same year. Since 1966, some models have been made in Brylon, a synthetic material, and others in briar. The brand was also sold by the English company Cadogan and Oppenheimer Pipe.

I discovered very quickly that Brylon was not a line and that the Medico Apollo on the worktable was not briar! In 1966, an innovation was introduced by S.M. Frank of fashioning bowls from a synthetic material. At this point I’m thinking about Paw’s Apollo, whether I could repair it with the same procedures as with briars? Rim? Cracked shank? Blending repairs? The same Pipedia article continued later with this additional interesting information about Brylon:

The company ended up buying some of their main competition in 1955. That year the Kaywoodie brands came under the S.M. Frank Company. The Medico brand continued production through this transition without many changes. The next big change for the brand came in the late 1960s. In 1966, the company developed a synthetic material that combined the traditional briar wood with resins. It is known as Brylon. At that time, all Medico pipes were made from imported briar wood. In order to keep production costs down, the company began offering some lines with Brylon. Today, that is still true…. In the Brylon, the line includes the Lancer, Apollo, Standard, Varsity, Conqueror, Medalist, Cavalier, and V.F.Q. As far as price, the briar wood pipes tend to be higher in cost than the Brylon ones. Courtesy TobaccoPipes.com

In another Pipedia discussion of various material and construction methods used in pipe production lines generally, Brylon is identified as a “High Temperature Resin with Wood Flour”:

In 1966, S.M. Frank developed a material called “Brylon” made of a high temperature resin combined with “wood flour”, which is pulverized wood of varying consistency. The pipes were cheaper and more durable, but heavier in the mouth and had a tendency to smoke hot and wet. They are still made today and favored by some for their inability to be burnt out or otherwise damaged without significant effort and the ease of cleaning the pipe. For more information see S.M. Frank.

Well, the unique characteristics of Brylon are becoming more evident. They are less expensive, have differing smoking behaviors compared to their briar brethren and purportedly to be less susceptible to burning and damage compared to their briar brethren, BUT, (I love the qualifier!) “without significant effort”. I guess Paw’s proclivities were with significant efforts by the looks of his Apollo! Wow! I wonder if Sam took the durability billing of S.M. Frank as a challenge 😊?

The question now is whether the issues of this Medico Apollo are addressed differently than my normal briar restoration protocols? The significant issues start with the rim damage. With the restoration of the first of Paw’s Kaywoodies, he seems to have been a habitual bowl ‘knocker’ with consistent damage to the aft quadrant of the rim. Using the stem as a handle, Paw seems to have inverted the pipe and thumped the bowl on something hard enough to dislodge the ash and dottle – probably on his way hurriedly to the car after visiting a client, having secured his sale of B&W product line working toward ‘2-Page’ success, and speedily transitioning his mind and body to the next visit! I take a few pictures to show the aft rim damage.The shank also has a huge crack starting on the top of the shank running to the bowl crook. When I communicated with Joe before receiving the pipe, he commented about the stem’s metal filter housing being out of round. When I received the pipe, the stem and stummel were joined. When I gingerly extracted the stem from the mortise, I could see how the nickel had been bent. When I tried to rejoin the stem and stummel, the fit was so tight that I decided to leave things like they were. I began to question whether the stem was the original for this stummel and forcing it had caused the cracked shank? Yet, the stem does have the Apollo ‘A’ stamping – probably, just bent so much that the mortise no longer can accommodate it.The stem’s condition I believe is confirmation that ‘2-Page Sam’ often had the Apollo in a hands-free mode with it clenched between his teeth while he filled out his orders! The chewing of the bit is evident with severe chatter and bite compression. The oxidation appears to be minor.There also is a pit and dent mid-way on the stem’s underside which will need addressing.To begin the restoration of Paw’s Medico Apollo, I work on cleaning the internal airway with pipe cleaners wetted with isopropyl 95%. While cleaning, I discover that the pipe cleaners are obstructed at the bit-end of the stem. I also use a shank brush to push through. The shank brush does push through but what becomes evident is that the chewing of the bit appears have closed the airway to such a point, the pipe cleaners are hindered from functioning. This is a problem for keeping the airway fully cleaned. I’ll need to address this issue as well. When the airway is as clean as I’m able to get it, the stem is added to a soak of Before & After Deoxidizer along with other pipes in The Pipe Steward queue, along with Paw’s other 2 Kaywoodies.After a few hours, the Apollo stem is removed from the Deoxidizer and I squeegee the liquid off with my fingers then wipe the stem with cotton pads wetted with alcohol to remove the resulting raised oxidation.Following this, paraffin oil is applied to the stem to condition the vulcanite and I put the stem aside for the oil to be absorbed.Turning my attention now to the Brylon stummel, the questions I asked earlier about how to proceed with the repairs have been clarified in my mind. It was helpful to find a blog on Dad’sPipes, What the Heck is Brylon?? – A Yello Bole Standard Panel Billiard, where Charles Lemon had previously had the same questions regarding working on Brylon! Charles’ blog mainly was focused on cleaning and polishing issues and not with actual repairs to the Brylon – the rim and shank in this case. My note to Charles describes my proposed working approach with Brylon:

Charles, hope you and your family are well and staying clear of harm’s way during these difficult times. I read one of your blogs where you worked on Brylon. I’m working on a Medico Apollo Brylon that needs extensive rim work. I’ve attached a picture to give you an idea of the dark brown color. Of course, I’m thinking of briar dust and CA glue to do the patchwork. However, it will probably be lighter than the hue of this brown. Do you think adding a wee bit of dark brown aniline dye would work? Do you have any best practices, beyond the blog I read 😊. The default if patching doesn’t work is to top the stummel but that reduces the height.

Charles’ email reply came quickly: Hi Dal. Good to hear from you! I hope all is well with you and yours. I have not attempted to fill Brylon. To be honest I have avoided the stuff as there is limited resale value in it. I think you are right – briar dust will show paler against the brylon. Mixing in some dye may do the trick. If not, you can always top the bowl afterwards. Good luck with it. I’ll be interested to see the results!

Charles

Charles’ response was what I was hoping to hear regarding using a mixture of CA glue and briar dust, which is the main component of Brylon though briar is not specified as the wood component. The issue is the coloring. Fiebing’s Dark Brown Leather Dye, which is an aniline dye, I think might be a very close match, but I’ve never introduced dye to a CA glue before – what will it do? The worst-case scenario is that the patch doesn’t work and I top the bowl, turning it into a Pot shape. I’m thinking to first introduce just a small amount of the dark brown dye – a drop, to a puddle of CA glue and mix it thoroughly and see how the CA/dye mixture behaves. Then, as with briar repairs, if the glue/dye mixture looks good, I’ll introduce briar dust and see what happens! With this next day of quarantine in Bulgaria being beautiful, I work outside on my 10^th floor Man Cave balcony.

The first two pictures are marking the start – looking at the inside of the rim and then the outside.After preparing my plastic mixing palette by covering it with some scotch tape to help in the cleaning later, I place a small mound of briar dust on the palette and next to it, a small puddle of BSI Extra Thick CA glue.Using an eye dropper, I place one drop of Fiebing’s Dark Brown Leather Dye in the middle of the CA puddle and it immediately expands through the puddle. Not able to take any additional intermediate pictures to chronicle the mixing – the clock starts ticking when the briar dust is introduced to the CA glue. I used a toothpick to gradually pull briar dust into the CA/dye, mixing as I go. I noticed that the CA mixture thickened more rapidly than normal with the dye alone, but it didn’t solidify which was what I was concerned about. When the mixing came to a point where the resulting putty was about the consistency of molasses, I troweled the putty to the rim to fully cover the damaged area. This picture shows the progress at this point and a bit of wind-blown briar dust on the Man Cave!I use an accelerator to hold the patch material to the rim – it did want to move a bit. Examining the patch in the sunlight, I’m VERY pleased with the color. It appears to be very, very close to the Brylon at this point in the process. With the same approach now as with briars, I start with the outer rim and file the patch mound down to near-flush with the Brylon surface. Before moving to the inside and top of the patch, I use 240 grade sanding paper on the external rim patch. I’m anxious to see what it does. As I sand, pockets do appear in the patch area in this rough state.Switching to the internal rim patch area, I mount a sanding drum to the Dremel and bring the patch down to flush.Carefully, I use the drum on the top as well. I do not want to be too aggressive by sanding below the plane of the rim with the more powerful mode of sanding. Following the sanding drum, continuing with 240 paper wrapped around a Sharpie Pen, the chamber is sanded to help blend the patch area and to clean the chamber. Then 240 sanding paper is redeployed to fine tune the rim contours and to smooth the patch. The color match is looking good but at this rough state, the patch area on the rim reveals the air pockets which I’ll work on masking in the later stages. Having reached this point in the repair on the rim, before doing more sanding to improve the rough patch area, I address the shank crack. The question rolling around in my mind regarding Brylon is whether I should drill a counter-crack creep hole at the end of the crack? The crack ends at the shank/bowl merger. The two pictures show the crack and a closeup of the end of the crack. Working on the Man Cave balcony, the best angle of sunlight to see the crack was in the flower box hanging over the edge of the balcony with signs of early spring sprouting in Bulgaria!Marking the end of the crack with an arrow, the crack has turned the vertical corner and is on the bowl side – just slightly. Since this is the first time working on Brylon and I haven’t found others who have complied a list of ‘best practices’ working with Brylon, I decide to drill the hole to be on the safe side. Earlier, I had decided not to reinsert the stem because it seemed that it was too tight and may have caused the crack. I’m thinking that the best way to address the crack is first, to drill the counter-creep hole. Following this, carefully reinsert the tight stem and allow the nickel filter housing to expand the crack allowing thinner, regular CA glue to seep into the cavity assuring a stronger bond. I’ll then remove the stem, closing the crack and hopefully removing the threat of the crack advancing. I’ll be thinking about whether to use a band to protect the shank for future use.To prepare to drill, I use a sharp dental probe to create a guide hole for the drilling. It took the use of a magnifying glass to identify the end of the crack. Unfortunately, there was a bit of collateral damage, but nothing serious. When I applied pressure to the dental probe to imprint the indentation for a guide, I discover the Brylon to be much harder than briar and with the additional pressure that was needed, the probe skidded off to scratch the stummel. Ugh! – it will sand out later.Next, after mounting a 1mm drill bit onto the Dremel, I carefully drill a hole using the guide hole – a great help in keeping the hand-held drill bit from dancing around! I’ve gotten better at drilling these holes freehand with the handheld Dremel extension – my main work tool.With the hole drilled, with fear and trembling I coax the filter housing into the mortise and as expected, the terribly tight fit helps expand the crack for a more effective application of CA glue. I must be honest; I was bracing myself for the stummel to split, but thankfully it didn’t! I will address the fit later after the shank is repaired and stabilized.With the crack expanded, a line of regular CA glue is run starting from the hole down the shank to the shank facing. After laying down the glue, the stem is extracted, and the crack again compresses with CA glue in the cavity.For some cosmetic help and to keep the glue in place, I sprinkled the glue line with briar dust. I put the stummel aside to allow the glue to cure.With the Brylon bowl on the sidelines, I turn my attention to the stem. The first step will be to repair the chewed bit – Two-Page Sam’s trademark! I take fresh starting pictures of the upper and lower bit to show the carnage. After each of these, is the comparison picture after using the heating method to minimize the damage. Using a Bic lighter the bit is painted with the flame heating the rubber and helping it to expand to regain some of its original disposition. I think the heating definitely improved the minor chatter so that for the upper bit, sanding should be all that is needed with some filing to freshen the button. For the lower bit, again, chatter was minimized but patching will still be required for the compressions.Medium-Thick Black CA glue is used to do the fills. After filling the deep compressions, I set the stem aside to allow the CA glue to cure.After the fills have cured, a flat needle file is used to file down the patch mounds and to shape and refresh the button.The upper bit also is the recipient of the filing to file out the more severe chatter and shape the button.After the filing, 240 grade paper is used to further smooth the upper and lower bit. The repairs on the lower side are looking good. About mid-way on the lower side of the stem there is a dent and a divot. I expand the 240 paper sanding to the entire stem to address these issues and to remove any oxidation hanging on. I’m careful to guard the Apollo ‘A’ stamping from the sanding. Before going further with the fine sanding, I remembered that earlier that it was very difficult to clean the stem’s airway because the bit area was too compressed from Paw’s chewing the bit. To address this, I start a new pipe cleaner down the airway while warming the bit with the hot air gun. I warm it on the upper bit avoiding the fills that are on the lower bit. I do this to avoid dislodging the fills which will not expand the same as the rubber.It works like a charm. As the vulcanite warmed it becomes supple and I move the pipe cleaner gradually through the airway as the compressed area relaxes. When the pipe cleaner is moving freely and normally, with the pipe cleaner remaining in the airway, I run the stem under cool tap water setting the expansion in the vulcanite airway.Next, the entire stem is wet sanded using 600 grade sanding paper followed by applying 000 grade steel wool as I normally do with briars. The nickel stem facing and filter housing also receive attention from the steel wool and clean up very nicely.Putting the stem aside, I focus on the shank repair. The glue has cured, and I use 240 grade paper to clean away the excess patch material from the surface of the shank. The half-rounded needle file helps to remove the thicker patch buildup at the crook of the shank and bowl.Charles Lemon’s blog on ‘Dad’s Pipes’ was helpful to know what to expect working on the sanding and polishing of Brylon – or, what NOT to expect. He found that Brylon does not polish up like briar but remains somewhat speckled and a dulled finish. With my repairs on the Brylon being more intrusive than Charles’ experience, my concern is for the overall blending of the surface. Will the area of Brylon that has received more focused 240 sanding appear differently from the other areas in the end? To avoid this, I decide to encourage overall blending beginning with wet sanding the entire bowl, including the patch, with 600 grade paper. This is followed with applying 000 steel wool. The following pictures show the result – a darkening of the Brylon finish and with the uniform blending that was my hope. This result encourages me to continue the fine sanding on the Brylon surface but also to continue blending the patches.Before moving forward with sanding and polishing of either the stem or stummel, one more technical challenge has yet to be remedied: the fit of the stem into the mortise. With the shank crack glued, the last thing I want to do is to crack it again! The picture shows the irregular shaping of the nickel housing. The starting place is to ‘re-round’ the housing. I use needle-nose pliers to do this. First, I heat the nickel with the hot air gun to encourage movement in the metal without splitting it. After heated, with the closed needle-nose pliers inserted into the nickel housing, I slowly turn the stem and apply gentle pressure to coax the nickel into a more rounded orientation. Patience is key! Not perfect, but much better. I don’t want to put too much stress on the nickel, so I decide to stop.No surprise – I try a half-hearted attempt to engage the stem and stummel but fit remains too tight. The next step is to relieve the internal mortise pressure. I find a drill bit small enough to accommodate being wrapped with 240 grade paper and able to navigate the mortise. Once, I get the best fit, I sand the mortise and attempting to fit the stem as I go. It becomes clear that the roundness, or lack therein, of the filter housing was continuing to cause problems with ‘high spots’ as I attempted to rejoin the stem. After returning to the hot air gun and making further adjustments to the nickel housing, I achieved a round housing that fit BUT the adjustment now left the housing lose in the mortise…ugh. The restoration nightmare – repairing a repair.The solution I decided on was to rebuild the internal mortise grip by painting the mortise with acrylic nail polish. I paint the mortise walls with the small brush provided, wait for it to dry and then paint it again, adding an additional layer. This was not part of the plan…After several revolutions of adding layers of acrylic polish, the grip in the mortise was restored. A detour but moving forward!The full regimen of micromesh pads is applied to the stem starting by wet sanding with pads 1500 to 2400 followed by dry sanding with pads 3200 to 4000 and 6000 to 12000. Between each set, Obsidian Oil is applied to condition the stem and protects it from developing oxidation. The stem is looking good! I decide to run the Brylon stummel through the full micromesh battery as well. I’m not sure it will enhance the shine much, but I want to continue the process of blending the entire stummel surface, including the rim patch. Wet sanding begins with pads 1500 to 2400 and is followed by dry sanding with pads 3200 to 4000 and 6000 to 12000. The results are good. The surface did shine up and the color deepens. Before applying Blue Diamond compound, I want to apply some cosmetic touches. The crack in the shank is visible as a lighter line. The large rim patch is speckled as well. Using a walnut colored dye stick, I apply it to the shank and to the rim with very nice results. The dye helps the blending. Next, to continue with polishing, I apply Blue Diamond compound to the stem and stummel after mounting a cotton cloth buffing wheel to the Dremel with the speed set at about 40% full power.After completing the application of Blue Diamond, one more cosmetic project awaits attention before applying wax. The Apollo ‘A’ stamping needs refreshing. I apply a small dab of white acrylic paint over the stamping.Then, with a cotton pad, I tamp the paint drawing off the excess paint leaving a thin layer of paint over the stamping which dries very quickly.Then, using a toothpick’s flat side, I lightly scrape over the stamping to remove the excess paint leaving behind the paint in the imprint. The ‘A’ appears to be partially worn and the paint only hold where the imprint is deep enough. It looks good!Finally, another cotton cloth buffing wheel is mounted onto the Dremel, set at the same speed, carnauba wax is applied to the entire pipe. The Brylon doesn’t absorb like briar so the wax seems to only make a very superficial shining on the surface. Because of this, very little wax was needed on the surface.After completing the wax application, the final step in the restoration of Paw’s Medico Apollo Brylon was to give it a rigorous hand buffing with a microfiber cloth to raise the shine.

This restoration was a challenge but worth it! Working with Brylon has unique challenges but it was good to learn more about how it behaves in case I have another S.M. Frank innovation come across my worktable! The rim patch worked well but speckling remains as a reminder of Paw’s knocking activities! In the end, this pipe of Paw’s legacy is ready to go again bringing with it the memories of the man called, ‘Two-Page Sam’ to be remembered and treasured by his family. Thanks for joining me!

Cleaning up a Unique Savinelli Made Antique Shell 623 Bulldog

Fashioning a Churchwarden from a Blasted French Dr. Geo Deposée Bowl

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Blog by Dal Stanton

This is the second commissioning project for the pipe man, clam man, Jon, from South Florida. His first commissioning (see: A Striking Savinelli Fiammata 2 Briar Calabash for a Clam Man Pipe Man) turned out to be a diamond in the rough! He had commissioned this pipe not from the usual perusal of my online ‘Help Me!’ baskets in the For “Pipe Dreamers” Only! collection, but he had visited us here in Sofia, Bulgaria, along with a team of folks from his church. During this visit, Jon went through the boxes and baskets of the inventory and found the Savinelli Fiammata and pulled him aside to commission. During this visit, Jon also saw my personal collection of Churchwardens and offered to give one of them a new home! In the end, Jon also commissioned a CW project which also benefits the Daughters of Bulgaria, our work here in Bulgaria working among women and girls who have been trafficked and sexually exploited. This was also important to Jon, who as a father, had brought his daughter with him to Bulgaria. My goal in fashioning Churchwardens from bowls that were either orphaned or in their current states had little hope of being put in service again. I liken it to Santa’s mythical island of misfit toys. Repurposed bowls mounted on CW stems can rise from ash heap, as it were, to live and serve again. I sent Jon a picture of different bowls to see which would speak to him as his new Churchwarden. He had told me he preferred a bent shank – here were the candidates with differing characteristics.Our emailing back and forth between South Florida and Bulgaria to identify the bowl speaking Jon’s name, resulted in the French Blasted Dr. Geo Deposée, the second pipe pictured above. I acquired the Dr. Geo during one of our summer vacations on a pipe picking expedition to the Bulgarian coastal city of Burgas on the Black Sea. I found the ‘Burgas Lot of 9’, at a secondhand shop on the main walking street. The Dr. Geo is at the end of the line of 7 pipes pictured below which were part of the haul – 2 others were added to these that were eventually posted in the For “Pipe Dreamers” Only! collection from which pipe men and women can choose and commission.The Dr. Geo I acquired I called a Prince shape. I knew nothing about a Dr. Geo line, but what attracted me to the pipe was the blasted bowl – it was tired and dull, but had potential, though the pipe itself was unimpressive and attracted no attention when it had its time in the Dreamers collection.With the bowl now on my worktable to transform into a Churchwarden, I found some information online about the origins of Dr. Geo Deposée. Pipephil.eu’s panel gave some information confirming that it was of French origins from the Gichard & Cie Company.Pipedia adds some additional information in its list of French made brands. It lists that Dr. Geo was produced in the 1940s from Guichard & Cie, and later sold by M. Marmet Regge, with Ebonite stems. Interesting to me is that my guess is that The Dr. Geo I’m looking at was from the later, M. Marment Regge ownership with the specific reference to the use of Ebonite stems. I have another Dr. Geo in my Dreamers inventory from another Lot I purchased from France, it has a horn stem, which most likely places it in the earlier dating when rubber was in short supply during WW2. The listing for Marmet in Pipedia, called M. Marmet-Regge, also sold the Dr. Geo brand which were produced in Saint-Claude. The meaning of the French, “Deposée”, attached to Dr. Geo is a bit cryptic, at least to one who is relegated to Google Translate to make sense of the meaning. The direct primary English translation provided is “deposited” which is a past tense rendering. Looking at other definitions provided by Google Translate, the possible meaning could be tied to the idea that “Dr. Geo” attests to or is behind the goodness of this pipe brand like Dr. Grabow! It seemed like I was grasping at straws until I see the ‘info link’ on the Dr. Geo panel provided by the Pipephil. The link goes to a French site called ‘Ces pipes pas comme les autres’ (These pipes like no other) to a May 2006 listing selling ‘Two Doctors’ pipes with information about each. A ‘Dr. Geo’ is described as one of the doctors with the possible clue pointing to a rational for the sub-name of ‘Deposée’:

Many pipe brands have earned the doctoral title. This makes smokers smile during these times of heightened hunting.

During the post-war years this title was more a guarantee of seriousness or of a search for perfection rather than the sign of a healthy practice. We did not allow ourselves to be disturbed by medical considerations. Everyone knew that smoking was not very healthy and took responsibility. But that has changed a lot today with the new globalized MacCarthyism.

José Manuel Lopes (1) counts seventeen brands of pipes that bear the famous title! I would like to introduce you to an 18th: Dr Arthur recognizable by his “A” circled on the pipe. No further information on this doctor there Maybe you thought I was going to present you with a leather-wrapped pipe, stamped with the most famous of these doctors? It would be bad to know me. But fear not: in this section you will not escape the famous Franco-English doctor whom I have already mentioned in the section of Cavalier pipes.

The pipes of Dr Géo – French brand of Gichard & Cie which is no longer produced – do not have an exceptional notoriety but sufficient to be cited here and there.

(1) José Manuel Lopes (President of Pipe Club of Portugal), Pipes, Artisans and Trademarks. Quimera Editores, 2005

The listing shows a picture of each Doctor cited with dimensions and a pricing. I find interesting the dismissive gesture for the listing for the Dr. Geo: “…no longer produced – do not have an exceptional notoriety but sufficient to be cited here and there”. My hope is to change the demeanor of the Dr. Geo Blasted Prince bowl on my worktable transforming him into a Churchwarden. Churchwardens as a classic pipe shape are unique among pipes. Bill Burney’s description of Churchwardens on his great Pipedia shapes page, describes why they are unique among pipes:Working on my Man Cave 10^th floor balcony, I take a few more pictures to get a closer look at the Doctor Geo Prince bowl, which is essentially an Apple shape without the Prince stem – hmmm, an exception to the CW stem principle? The blasted finish is nice – the smooth 3-D picture of the bowl’s grain structure is nice. The finish on the stummel appears to be a very dark brown. There are minuscule red flecks visible through the cloudiness of the old finish. At this point, my thinking is to refresh the finish seeking to apply the ‘Dunhill’ finish that I learned from fellow-restorer and rebornpipes contributor, Paresh. First, after applying all the paces in cleaning the stummel, I’ll assess the condition of the stummel and how to proceed. Following this, fashioning the CW stem will come. To start, the Dr. Geo chamber is moderately caked. To address this, I employ the Pipnet Reaming Kit using only the smallest of the 4 blade heads available in the kit. I follow by scraping the chamber walls with the Savinelli Fitsall Tool and complete the carbon cake removal by sanding the chamber walls with 240 grade paper wrapped around a Sharpie Pen. After wiping the chamber with a cotton pad to remove the carbon dust, an inspection reveals a healthy chamber.Transitioning to cleaning the exterior surface, using undiluted Murphy’s Oil Soap, I go to work using a cotton pad and a bristled toothbrush. The brass bristled brush also works on the rim.Next, I take the bowl to the kitchen sink to continue the cleaning with shank brushes and anti-oil liquid dishwashing soap to clean the internal mortise and airway. After giving the bowl a thorough rinsing with warm water, I transfer it back to the worktable.Through the cleaning, the finish has started to come off. This is an indicator that a fresh start is needed. The finish is old and unstable.I decide to remove the old finish to get to the fresh briar beneath. Isopropyl 95% is the first agent I try scrubbing the blasted finish with a cotton pad. It is not effective.Transition next to using acetone is much more effect. The cotton pad is evidence of the old stain which appears black and purple. I decide to put the entire stummel into an acetone soak to fully remove the finish. I leave it in the soak for a few hours. After a couple hours the jar containing the stummel soaking in acetone is clouded with leeched finish. After taking the stummel out, I use a cotton pad to continue rubbing the finish off as well as employing a little steel wool. The light spots that appeared first are areas that were filled, at least partially, with wood putty which have weakened due to the cleaning. I use a sharp dental probe to test the fills and they are solid. With the rough texture of the blasted surface, these areas will not be visible after applying new dye to the stummel. Before doing more work on the stummel, I switch the focus to fashioning the CW stem. The first thing I do is to bring out the electronic caliper and measure the diameter of the mortise which gives me the target size of the tenon that needs to be shaped. This measurement is 7.81mm. I add about 40mm to this to form my ‘fat target’ – the size I’ll cut the tenon and then follow by sanding to form a customized fit to the mortise. The fat target is about 8.20mm. Next, with the drill bit provided by the PIMO Tenon Turning Tool, I predrill the airway to accommodate the guide pin of the TTT. Next, after mounting the PIMO tool on the hand drill, I do a test cut on the raw tenon of the precast CW stem and measure it – 8.01mm on the button. Whoops – that is 20mm less than I was aiming for as the ‘fat target’ but I decide to cut the tenon at this size and then sand. This gives less margin of error, but I’m not too concerned. Keeping the same adjustment of the PIMO tool, I continue the test cutting to form a I have made several Churchwardens and one of the mistakes I have learned is to cut the tenon all the way through the precast uneven molding to create a true stem facing. Not to do this will leave what appears to be shouldering over the edge of the stem facing. The picture below shows a sharp 45-degree angle which is the goal.Next, using 240 sanding paper, I sand the newly cut tenon to bring it closer to the target mortise size – 7.81mm. The rough end of the precast tenon is flattened and smoothed using the flat needle file.After a short time of sanding and fitting, the tenon seats into the mortise.Looking closer, there is a small gapping on the right side which I can close during the fine-tuning sanding.What is also the case is that there is a small overhang of the shank over the seated stem. This will need to be sanded so that the transition between stummel and stem is smooth.I use masking tape to protect the nomenclature as well as to give a sanding boundary around the shank.I start the sanding on the shank/stem transition. What is helpful shown in the picture below is that it shows what the ‘low-spot’ is in the pre-cast stem in the darker area passed over by the sanding indicating where sanding continues to be needed. As often is the case with the pre-cast CW stems I purchase, the shank facing along the casting seam has a dimple. This is a pain because these dimples simply mean more sanding required at those points.Progression with the dimple – I don’t want to take off more than needed. Note, the darkened area has disappeared on the stem indicating that the sanding paper is making seamless contact between shank and stem.With the shank/stem transition sanding completed, I move to sanding the entire pre-cast CW stem. To start, I use a coarse 120 grade paper to do the initial sanding. The casting seams along both sides of the stem need to be erased. The following picture again shows the differences in the surface of the pre-cast stem. The pre-cast stem has ripples – unevenness, even though it is new. The dark stretch below shows a ‘valley’ in the rippling that means I sand more there to bring the edges of the valley flush with the valley floor. The following pictures show the progression in the 120 sanding.With the CW stem smoothed after the 120 grade sanding, I switch to fine-tuning the button. As with the stem, the button is rough. The bit needs filing to flatten it and to bring more definition to the button edges. The slot facing on these CW stems is curved and the upper button extends out a bit more than the lower. This helps in identifying the up/down orientation of the stem. The pictures show the progression with upper and lower bit. Upper first:Lower :After the main filing is completed, 240 grade paper is employed to fine-tune the bit and button as well as to sand the entire stem after the 120 sanding. Upper and lower first: Next, to continue the smoothing, 600 grade paper is used to wet sand the entire stem. This is followed by applying 000 grade steel wool.A closeup of the button area shows the nice progression!Next, the full regimen of 9 micromesh pads is applied from 1500 to 12000. Between each set of 3 pads, Obsidian Oil is applied to condition and protect the vulcanite from future oxidation. I only show one orbital view and a couple closeups of the finished process focusing on the upper and lower bit. With the CW stem’s sanding completed, its time to bend the stem. The general principle I follow in stem bending is that the mouthpiece at the end of the stem, should be generally on the same horizontal plane as the rim. It’s helpful for me to draw templates to visualize the finished stem.Where the original stem template starts with and estimation of where the bend should take place.I use the hot air gun to focus the heat on the lower side of the stem first – the thicker part. I want it to become supple before heating the upper, thinner area of the stem which heats faster and wants to be the first place the bend begins. I want the bend to start in the thicker part of the stem then followed by the thinner.As the stem warms over the hot air gun, I gently coax the bend as the stem softens. After bending to a point that looks good, I bring the stem to the template holding it there for some minutes for the orientation to take hold. I then take the stem to the kitchen sink and run cool water over it to solidify the bend. The first try works well. I like the look and feel of the pipe in my hand.With the stem sanding and bending completed, focus is again transitioned to the Dr. Geo blasted bowl. Before moving to the staining process, the stummel needs some preparatory work. One of the things I really like about working with a combination of blasted and smooth briar surfaces is the contrast that this produces. I love to see both presentations of the grain – the smooth 2-D viewpoint as well as the rough, blasted 3-D viewpoint of the grain. This bowl provides an opportunity for the striking contrasting. The rim is angled in a beveled slope from the external rim’s edge downward toward the chamber to the internal rim’s edge. This rim, I believe, will look great after it is sanded to bring out the smooth briar contrast.The other sanding will bring out smooth grain over the nomenclature panel on the left shank flank as well as the newly sanded area transitioning to the stem. To begin, 240 grade paper is used on these smooth briar patches followed by dry sanding with 600 grade paper. The full regimen of 9 micromesh pads, from 1500 to 12000, is applied to the smooth briar patches next.I’m loving what I’m seeing! That grain contrast is great. In the second picture, the rough area from the old fill is still visible and looks shaky, but it should disappear as it blends with the surrounding briar after the staining process.The staining process is next. I assemble my desktop staining module with all the component parts. I recently used the method I learned from my fellow restorer from India, Paresh, of creating the rich Dunhill look. With this bowl being originally darker, I thought that this approach would be good. It starts with an undercoat of Fiebing’s Dark Brown Leather Dye that is followed with the washing with red dye. After wiping the bowl with a cotton pad wetted with alcohol to clean it, I warm it with the hot air gun to open the briar helping it to be more receptive to the dye which is applied using a folded over pipe cleaner. Using the pipe cleaner, I paint sections of the bowl with the Dark Brown Dye and then immediately ‘flame’ it with a lit candle. This combusts the aniline dye burning away the alcohol leaving the dye pigment embedded in the briar. After applying the dye, the stummel is set aside for several hours – through the night, for the dye to ‘rest’ and settle in. This helps the dye to take hold in the briar.The next morning, it’s time to ‘unwrap’ the flamed stummel. To do this, a felt cloth buffing pad is mounted onto the Dremel set at the slowest speed, and Tripoli compound is applied to help remove the crusted shell exposing the dyed briar beneath.After the Tripoli compound removes the flamed crust, I wipe the bowl to rid it of the compound dust. When this is completed, I apply a wash of red overcoat to the briar surface and lightly wipe it with a cotton cloth. I apply and wipe until I’m satisfied with the hue. I like what I see. The rich red tones give a depth to the blasted finish.Next, since it’s easier to handle the stem and stummel separately, after mounting a cotton cloth buffing wheel to the Dremel set at about 40% full power, Blue Diamond compound is applied to the long Churchwarden stem and Dr. Geo bowl. One more step to guard against dye leeching. Often, bowls that have been newly stained, dye will come off on the steward’s hand the first times the bowl is heated up and put into service. To emulate this, I heat the bowl with the hot air gun and then wipe it with a cotton cloth to pick up leeched dye. Hopefully, this will keep the bowl from leeching later!I complete the fashioning of the Dr. Geo Churchwarden by giving the reunited stem and bowl a vigorous hand buffing bringing out the shine. I’m very pleased with the results of the ‘Dunhill’ approach to finishing the bowl that I learned from Paresh. The Dr. Geo Prince bowl serves well mounted on a long, flowing Churchwarden stem. The contrasting with the smooth and blasted briar surfaces also work very nicely. This was Jon’s second commissioned pipe and he will have the first opportunity to claim this French Dr. Geo Churchwarden from The Pipe Steward Store benefitting the Daughters of Bulgaria – women and girls who have been trafficked and sexually exploited. Thanks for joining me!

Cosmetic Repairs and Restoration of a Jobey Dansk 3 Freehand

Breathing Life into a Danish Hand Made Ben Wade Golden Walnut

Breathing Life into a Ben Wade Danish Made Ambassador Deluxe

1 Reply

Blog by Steve Laug

There is some almost electric about handling and working on a pipe designed and carved by Preben Holm. I can’t describe adequately the feeling I have when I turn the bowl and stem over in my hands even before I start working on the pipe. There is an energy that flows through the way he carved and shaped the pipes of his making. This pipe was no exception. When Jeff showed me the photos of several of the Ben Wade pipes by Preben Holm that he had picked up I was excited to be able to work on them. This one has grain that runs diagonally across both sides of the bowl culminating at a point at the heel of the bowl. The rim top combines smooth and plateau and the shank end explodes from the grain running into it with a tight plateau finish. The pipe was well loved as you can see from the thick cake in the bowl and the lava on the rim top. The inner edge of the bowl is burned, blackened and worn. The outside of the bowl and plateau portions are dirty and dusty but the grain pops through. There was a deep nick on the left side toward the bottom that would need to be dealt with in the restoration. The acrylic stem was dirty and dusty with deep tooth marks on the button surface and lighter ones on the blade just ahead of the button on both sides. Jeff took these photos before he started his part of the restoration. He took close up photos of the bowl and rim top from different angles to show the condition of both the smooth and plateau finish. You can see the lava and build up on the rim top and the lava flowing over the inner edge of the bowl. It is hard to know if there is damage or if the lava protected it. The bowl has a thick cake that lining the walls and overflowing into lava. The plateau surface is duty and also has some lava overflow in the valleys and crannies of the surface. He took photos of the sides and heel of the bowl to show the diagonal lay of the grain around the pipe. It is a beautiful piece of briar.Jeff took two photos of the deep gouge toward the bottom of the bowl on the left side. You can see the rough edges of the gouge in the photos. Steaming it would not raise the grain around that deep nick. It would need to be filled in and repaired. Jeff took several photos of the stamping on the underside of the shank to capture all of the stamping. It was clear and read Ben Wade in script at the top. Under that it read Ambassador Deluxe. Under that was stamped Hand Made in Denmark.The next two photos show the surface of the top and underside of the acrylic stem. You can see the tooth marks and damage both on the button surface and on the blade itself. The third photo shows the fancy turnings on the rest of the stem and give a sense of its flow.I remembered a bit of history on the brand that included the thought that the Preben Holm pipes were marketed under the Ben Wade label in the US and imported through Lane Ltd. I turned to Pipedia and read the listing on the brand to refresh my memory and flesh out the knowledge of the brand (https://pipedia.org/wiki/Ben_Wade). I have included a photo from that site that was taken from a Tinderbox advertisement.

Ben Wade Ad in a Tinder Box catalog, courtesy Doug Valitchka

I quote the portion of the article that summarizes the history of the brand.

Up to now Preben Holm made Ben Wade pipes are cult and highly sought for on the estate markets.

With that information my initial thoughts were confirmed. This pipe was a Preben Holm made Freehand distributed in the US by Lane Ltd under the name Ben Wade. The freehand rage occurred in the late 70s and the pipes were made until Preben’s death in 1989. My guess would be that this pipe was made sometime during that time period and potentially in the late 70s.

Armed with that information I moved forward to work on the pipe itself and see what I had to do with it. It had come back amazingly clean. Jeff had done his normal thorough clean up – reaming, scrubbing, soaking and the result was evident in the pipe when I unpacked it. I took photos of the pipe before I started my work on it. I took some photos of the rim top and stem to show the condition of them both when it arrived. It looked good. There is some darkening and damage to the inner edge of the bowl. The stem had some deep tooth marks ahead of the button and on the button surface on both sides.To begin my part of the restoration work I decided to repair the large chip/nick in the lower left side of the bowl. It was clean so I wiped it lightly and filled it in with briar dust and super glue.Once the repair cured I sanded it smooth with a folded piece of 220 grit sandpaper to blend it into the surrounding briar. I used a black Sharpie pen to stain the repaired area. I blended it into the surface of the surrounding briar with a Walnut stain pen. The photo shows the repair blended into the briar. I polished the bowl with micromesh sanding pads – wet sanding with 1500-12000 grit pads. I wiped the briar down after each pad with a damp cloth. The bowl is starting to look very good. I worked some Before & After Restoration Balm into the surface of the briar with my fingertips and into the plateau rim top and shank end with a horsehair shoe brush to clean, enliven and protect it. I let the balm sit for a little while and then buffed with a cotton cloth to raise the shine. The photos show the bowl at this point in the restoration process. I set the bowl aside and turned my attention to the stem. The stem was very clean so I filled in the tooth marks with clear super glue and set it aside to cure. Once it had cured I flattened out the repairs and sharpened the edge of the button with a needle file. I sanded out the tooth chatter with 220 grit sandpaper and started to polish it with a folded piece of 400 wet dry sandpaper. Once it was finished it began to shine.I used some Denicare Mouthpiece Polish that I have in my kit to start polishing out some of the scratches and remaining oxidation on the stem. I rubbed it in with a cotton pad and my finger tip and buffed it off with a cotton pad.I polished the stem with micromesh sanding pads – wet sanding with 1500-12000 grit sanding pads. I wiped it down after each sanding pad with some Obsidian Oil. I finished polishing it with Before & After Pipe Stem Polish – both Fine and Extra Fine and buffed it off with a cotton cloth. This is a beautiful Preben Holm made Ben Wade Ambassador Deluxe with a fancy, turned, black acrylic/Lucite stem. It has a great look and feel. The shape fits well in the hand with the curve of the bowl and shank junction a perfect fit for the thumb around the bowl when held. I polished stem and the bowl with Blue Diamond polish on the buffing wheel. I gave the plateau on the rim top and shank ende multiple coats of Conservator’s Wax. I gave the bowl and the stem multiple coats of carnauba wax. I buffed the pipe with a clean buffing pad to raise the shine. I hand buffed it with a microfiber cloth to deepen the shine. The pipe polished up pretty nicely. The rich combination of browns and black in the smooth finishes took on life with the buffing. The rich colour of the briar works well with the polished acrylic stem. I like the grain and finished look of this Preben Holm Ben Wade Ambassador Deluxe pipe. Have a look at it with the photos below. The shape, finish and flow of the pipe and stem are very well done. The dimensions are Length: 6 ¼ inches, Height: 2 ½ inches, Outside diameter of the bowl: 1 ¾ wide x 2 ¼ inches long, Chamber diameter: 7/8 of an inch. This Danish Freehand is a real beauty. Thanks for walking through the restoration with me as I worked over another beautiful pipe. This one will be going on the rebornpipes store shortly if you would like to add it to your collection. Thanks for your time.

Repairing a Burned Rim Edge and Chewed Stem on an English Ben Wade 76 Canadian

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Blog by Steve Laug

The next pipe on my table is nice sandblast thick shank Canadian. It is stamped on the underside of the shank with the Ben Wade over Made in London England. It also has the shape number 76 just ahead of the Ben Wade stamping. It has a nice sandblast finish that is in good shape under the dirt and even the rim top looks good. The inner edge of the rim is darkened but the bowl is in good shape. There was burn damage on the left outer edge and darkening on the inner edge of the bowl. There is a thick cake in the bowl and light lava build up on the rim top and inner edge. The taper vulcanite stem was oxidized and had some deep tooth marks and chatter on both sides ahead of the button. Jeff took these photos before he cleaned the pipe.He took photos of the rim top from various angles to give a clear picture of the condition of the bowl and rim. It is dirty but there is a light lava coat on the top and the rim edges have some darkening and buildup. There is also a deep burn mark on the left out edge toward the rear of the bowl. Jeff also took a closer photo of the burned area on the outer edge of the rim. It is visible in the photo below.The sandblast finish around the sides and heel of the bowl is quite interesting and reveals some different underlying grain. The stamping on the underside of the shank is very readable as can be seen in the next photo.The next two photos show the deep tooth marks on the surface of the stem. They are actually quite high up the stem from the button. This pipeman had been a bit of a chomper. There is some wear on the edge of the button as well. The stem shows a great profile. I moved forward to work on the pipe itself and see what I had to do with it. It had come back amazingly clean. Jeff had done his normal thorough clean up – reaming, scrubbing, soaking and the result was evident in the pipe when I unpacked it. I took photos of the pipe before I started my work on it. I took some photos of the rim top to show the condition of the edges and the bowl. It looked very good. There is some darkening to the inner edge of the bowl. The second photo shows the damage from the burn on the left side of the rim top and side of the bowl. The stem had some deep tooth marks ahead of the button on both sides. The bowl was going to be straightforward to work on so I started with it. The burned spot on the left side of the bowl edge needed to be addressed. Since the bowl was clean I wiped off the damaged spot with alcohol on a cotton pad. I dried it of with a cloth. I then filled it in with layers of super glue and briar dust – repeating the process until the surface of the rim top and the side of the bowl were even. When the repair had cured I sanded it with a folded piece of 220 grit sandpaper to blend it into the surrounding briar. I used a brass bristle brush to roughen up the surface of the rim top and side of the bowl. I worked it over to achieve a similar pattern to the surround sandblast. I stained the repaired area with a Mahogany stain pen and blended it into the surrounding stained briar. I am pretty happy with the match. At this point in the process the bowl definitely looks better.I worked some Before & After Restoration Balm into the briar with my fingertips. I let the balm sit on the briar for 10 minutes the buffed it off with a soft cloth. The balm enlivens, enriches and protects the briar while giving it a deep glow. I set the bowl aside and turned my attention to the stem. The stem was very clean so I filled in the tooth marks with clear super glue and set it aside to cure. Once it had cured I flattened out the repairs and sharpened the edge of the button with a needle file. I sanded the stem with 220 grit sandpaper to blend in the repairs with the rest of the stem surface. I started the polishing with 400 grit wet dry sandpaper.I polished the stem with Denicare Mouthpiece Polish. It is a gritty red paste (similar in grit to red Tripoli) that I rub on with my finger tips and work it into the surface of the stem and button and buff it off with a cotton pad. It gives me a bit of a head start on the polishing work.I polished the stem with micromesh sanding pads – wet sanding with 1500-12000 grit sanding pads. I wiped it down after each sanding pad with Obsidian Oil. I polished it with Before & After Pipe Stem Polish – both Fine and Extra Fine. I buffed the stem with a soft cloth to raise the shine. I wiped the stem down with Briarville’s No Oxy Oil to preserve and protect the stem surface. Ahhhh…once again I am at my favourite part of a restoration – finishing up a pipe! This Ben Wade English made Canadian 76 came out really well considering the issues with the burned area on the side of the bowl and rim when I started. I put the pipe back together and buffed it with Blue Diamond polish on the buffing wheel. I polished the bowl with multiple coats of Conservator’s Wax and the stem with multiple coats of carnauba wax. I buffed it with a clean buffing pad and with a hand buff with a microfibre cloth. The mix of colours and the buffing made the sandblast stand out when it was waxed. The mixed grain is quite stunning. Thick oval shank and taper stem stands out in great contrast to the briar. It is a nice looking pipe. Have a look at the photos below of the finished pipe. Its dimensions are Length: 6 ¼ inches, Height: 2 inches, Outside Diameter of the Bowl: 1 3/8 inches, Diameter of the Chamber: ¾ of an inch. The long shank Canadian feels great in the hand. This one will be going on the rebornpipes store later today. You can add it to your collection and carry on the trust. Let me know if you are interested in adding it. Thanks for your time.