Tag Archives: shaping a stem

Banding and Restemming a Weber Blackthorne 485

I just finished refurbishing the last of the EBay lot, the second pipe down in the centre column of the photo below. It is stamped Blackthorne over Weber in an oval and Imported Briar 485 on the underside of the shank. The Weber was probably the easiest pipe of the lot to restem and clean up. The bowl was lightly caked and the rim had a light buildup of tars on it. The blast is quite nice on the bowl and when I first saw it thought it might be a GBD Prehistoric. The rim is crowned upward from the bowl and also sandblasted. The bowl is stained with a dark brown and black contrast stain which leaves much of the black stain in the crevices of the bowl and the brown on the higher portions. The shank had some darkening from the end toward the bowl for about a ½ inch – like it had had a band on it at one point. There were no cracks in the shank so the band must have been cosmetic in function. The shank was thick and gave the pipe a chubby look. I am not sure whether to call the shape a chubby billiard or a pot. The inside of the shank was not terribly dirty would take little to clean up the pipe and ready it for a smoke.

I searched through my box of stem and found one of a suitable diameter to fit the pipe. I had the perfect match but it was a bent so I heated it with the heat gun and straightened it out. I used the PIMO tenon turning tool to clean up the tenon and make it straight. In the picture below the tenon appears to have a slight conical shape to it. After turning it the tenon was a cylinder that fit well in the shank.

I took out a nickel band that would fit the shank and then used the Dremel to smooth out the portion of the shank that would have the band. I find that a band seats much better when the surface that it is pressed onto is smooth rather than blasted or rusticated. I slipped the band lightly on the end of the shank and heated it with the heat gun to expand the metal and make the band simpler to fit on the shank. I pressed it into place on a metal plate that I use for a flat surface to press bands.

With the band in place on the shank the tenon needed a slight adjustment with sandpaper to fit well against the shank.

I reamed the pipe with a PipNet reamer and took the cake down to the briar. I scrubbed the top of the bowl with a cotton pad and Murphy’s Oil Soap to remove the buildup of tars. I gently wiped down the exterior of the bowl with the Oil Soap as well to remove the grime in the grooves and crevices of the finish.

I polished the bowl with Halcyon II wax and buffed it with a shoe brush. I cleaned out the shank and the bowl with pipe cleaners and Everclear and put the stem in place for the photo below. Once finished this will be a handsome pipe. I sanded the stem with micromesh sanding pads from 1500-12,000 grit to polish and remove any scratches left by the heating and straightening. I took the pipe to the buffer afterwards and buffed the stem with White Diamond and Blue polish to give it a shine.

I polished the nickel band with a silver tarnish polishing cloth and then waxed the stem with several coats of carnauba wax. I touched up the areas of the rim and the rim outer edge with a black permanent marker to cover some of the scratches in the finish of the bowl in those places. I buffed the pipe lightly on the buffer with White Diamond and gave the stem another coat of wax. The finished pipe is pictured below.

Restemming a Bruyere Krone Billiard

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I am just about finished restemming the lot of pipe bowls I picked up on EBay. This is one of the last two pipes that I have left in the lot below. It is the fourth pipe down in the left column. It has an interesting rustication pattern that reminds of one that is done on Saseini pipes. It is striated around the bowl and then tapers up from the bottom to a striated pattern around the shank. It has a flat bottom on the shank that is smooth and stamped Bruyere in a crown with a large R in the centre of the band on the crown. Underneath the crown is an unfurled banner that is stamped K R O N E. I have no idea of who the maker is or when and where it was made. The stamping is faint so I may be missing a few letters but I think this is an accurate rendering of what is stamped. The finish was pretty dirty with grime in the grooves on the bowl and shank. The rim was caked with a tarry buildup and the grooving on the rim was not visible. There were also place on the finish where the stain was missing and the briar underneath exposed. The inside of the bowl had dust and cob webs and a pretty large cake buildup that would need to be removed. The bowl came without a stem and fitting one would take flattening of the stem on the underside to match the shank.

I went through my box of estate stems and found one that was a good fit to the shank. Once the cleanup of the stem was done and a flattening of the underside of the stem the pipe would look like it came with that stem. The stem had a calcified buildup around the button and some tooth marks as well. The oxidation was not too bad but was present.

The clean angles of the button against the stem were gone so I recut them with needle files to clean up the edge. I reamed the bowl back to bare briar with a PipNet reamer starting with the smallest cutting head and progressing to the one that was the diameter of the bowl without the cake. Once it was cleaned out I scrubbed down the bowl with Murphy’s Oil Soap and a soft bristle tooth brush to remove the grime. I scrubbed the buildup on the rim with a soft bristle brass tire brush to remove the tars. Once I had scrubbed it I rinsed it with warm water to remove the soap and dried it off with a cotton towel. I wiped down the bowl with acetone on a cotton pad and prepared it to be stained. After heating it with a heat gun I stained it with a dark brown aniline stain. I used a permanent black marker to touch up the raw briar areas where it was scratched or damaged. I reapplied the stain and flamed it. The newly stained pipe is shown in photos 2 and 3 below.

I sanded the stem with medium grit emery paper to remove the calcification around the button and also heated the tooth marks with a Bic lighter to lift them as much as possible. I “painted” the surface of the stem with the flame to burn off the sulfur of the oxidation that I had loosened by sanding. I repaired the tooth marks on both sides of the stem with black superglue and set it aside to dry overnight.

The next morning I cleaned out the bowl and shank with pipe cleaners, cotton swabs and Everclear. I sanded the stem and the superglue patch with 220 grit sandpaper and then with a medium grit sanding sponge to clean up the scratches in the finish. I put it back on the bowl to get an idea of the overall look of the pipe and see if the diameters of the stem fit the shank. I needed to flatten the bottom of the stem some more to match the bottom of the shank and also removed some more of the material on the diameter of both sides to bring it into line with the shank. Once the stem was well fitted I moved on to sanding with micromesh sanding pads from 1500-12,000 grit.

I buffed the stem with White Diamond and a Blue polish. I gave the bowl a light buff with White Diamond to bring up the shine. I gave the bowl a coat of Halcyon II wax and buffed it by hand with a shoe brush. I gave the stem multiple coats of carnauba and buffed it on the buffer with a clean flannel buff. I think the pipe came out well. Does anyone know anything about the brand?

Making a New Stem for a Peterson’s Kildare XL999

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The Peterson’s Kildare is the second pipe down in the left column in the photo below. The second and third photos are of the pipe bowl apart from the lot. The externals were in pretty decent shape but the rim has a heavy buildup of tars and the cake in the bowl is quite thick and hard. To give an idea of the thickness of the cake I was unable to put my little finger in the bowl. The shank was quite large – the tenon is ½ inch in diameter for a snug fit in a clean tenon. The shank itself is 7/8 inches in diameter. It is a large mortise and airway. The pipe is stamped Peterson’s “Kildare” on the left side of the shank and Made in the Republic of Ireland XL999 on the right side of the shank. The finish is quite clean. The top will need to be topped to remove the buildup and dents. I also will need to chamfer the inner edge of the rim to repair the damage that is present on the surface of the rim.

I reamed the pipe with a PipNet Reamer beginning with the smallest cutting head on the T handle and working up to the diameter of the bowl. I carefully ream the cake so as not to damage the bowl roundness or the inner edge of the rim any more than it already is. I emptied the carbon out of the bowl repeatedly until it was clean and empty. I reamed the cake back to bare wood to begin to rebuild on a clean surface. I scoured the bowl and shank with Everclear and cotton swabs and pipe cleaners.

Once the inside was clean I decided to gently top the bowl. I used a medium grit sanding sponge flat on the table top and worked the rim against that to remove the buildup of tars. The first photo shows the set up and the second the result of the topping. Very little briar was removed from the rim, mostly tars. The finish however also was removed so the rim would need to be restained. The third photo shows how I used a folded piece of 220 grit sandpaper to bevel/chamfer the inner rim to repair the damage that had been done to the rim.

I sent out several emails and private messages to folks on the online forums to see if I could find a Peterson stem with these dimensions. I received many answers and several possible stems that could work for this pipe. Thanks to those who sent them. For the most part they were either too long or the diameter of the stem was not large enough to fit the shank. Chuck (desertpipe on SF) sent me several that would work. I also have a piece of brindle rod coming that Todd (Sasquatch on SF) was willing to cut for me. So in the end I will have two different stems for the pipe. While awaiting the arrival of the Cumberland stock I decided to turn the tenon on a vulcanite stem blank from Chuck. I turned it with a PIMO tenon tool and fit it to the bowl. The end fit was a ½ tenon for the mortise so I did not need to remove much of the existing vulcanite on the cast stem to make it fit well. To fit the stem on the tool I drilled the airway so that it slid easily over the pin on the tool but did not have too much play. I held the stem and ran the drill over the tenon for a first pass (second photo below) I adjusted the cutting tip and spun it several more times until the fit in the mortise was close. I used the Dremel with a sanding drum to take off more of the material and fine tune the fit (third photo below). I spun it one last time to clean up the face of the stem where it sat against the shank. I want that surface to be smooth and seamless in its fit.

After fitting the tenon to the mortise I used the Dremel with a sanding drum to remove the excess vulcanite on the diameter of the stem. I carefully sand with the Dremel and bring the stem as close to the diameter of the shank as possible without nicking the briar. I also sand down the sides of the stem to remove the casting overrun on the stem and button. The idea is to get as close as possible to the stem diameter and then sand the rest of the fit by hand with medium grit emery cloth and 220 grit sandpaper.

I took the pipe back to my work table and removed the stem and sanded it until the fit was perfect and the marks left by the Dremel were gone. The hand sanding is probably the longest part of the process of fitting a new stem. I sanded it repeatedly with emery paper and 220 grit sandpaper until it was smooth enough to move to the next step in the process. At this point I am not looking for a smooth and perfect fit but one that is getting close. I then heat the stem with my heat gun in order to bend the stem to fit the flow of the pipe. I heated it until it was pliable and then bent it over the rolling pin and cardboard tube that I use for getting the curve of the stem smooth and correct.

I took the pipe back to my table and showed it to my sidekick and helper, Spence for his approval. He gave it a sniff and looked it over. It passed his inspection so I continued to sand and shape the shank/stem union. Lots of pieces of sandpaper and emery paper later the stem is getting closer and closer to a good fit.

The button was very tight and I was not able to push a pipe cleaner through the slot so I opened the slot with needle files and reshaped it into an oval that was open and flared back to the airway in the stem.

I sanded the stem with a medium grit sanding sponge and a fine grit sanding sponge to remove the scratches left behind by the sandpaper. Each step of sanding brought both the fit and finish closer to the look I was aiming for with the finished stem.

I wiped the bowl down with acetone on a cotton pad to remove the finish and prepare the bowl for a new coat of stain. I have found that if I do not remove the stain then it is very hard to match the rim to the colour of the bowl. With the finish gone the staining is very simple.

I thinned the stain, a dark brown aniline stain, with isopropyl alcohol – 1 part stain to two parts alcohol. I had picked a stain that matched the previous colour of the bowl and also matched another 999 Peterson that I have here. I heated the surface of the bowl with my heat gun to warm the briar and open the pores in the wood. Once it was warmed I applied the stain with a cotton swab and repeated until I had good coverage over the entire surface. I flamed the stain, repeated the application and flamed it a second time. Once it was dry I took it to the buffer and gave it a light buff with White Diamond to even out the stain coverage and remove the excess on the surface of the briar. I wiped down the inside of the bowl where the stain ran in with a cotton swab dipped in Everclear.

With the bowl finished and ready to buff it was time to finish the work on the stem. I sanded it with micromesh sanding pads. I wet sanded with 1500-2400 grit and dry sanded with 3200-12,000 grit. Each successive grit brought more of a shine to the stem and removed the scratches left behind by previous sanding.

I worked on the slot with a folded piece of sandpaper to smooth out the surface of the inside. I also shaped it with the sandpaper until I had the look I wanted. The oval slot now easily took a pipe cleaner no matter how fluffy.

After much sanding and fitting, the vulcanite stem is finished. The pipe is smokeable while I wait for the Cumberland/brindle rod stock to come from Todd. I like the look and feel of the pipe as it is very close in size and design to the GBD 9438 with a tapered stem. The finished pipe is pictured below after buffing with multiple coats of carnauba wax and with a clean flannel buff.

Italian Made Sandblasted Canadian Brought Back to Life

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This pipe is another that came in that EBay lot of bowls that I purchased. Once I was finished with this one I have two more left to restem. It is a large oval shanked pipe with a large bowl. The sandblast is not deep and is particularly shallow on the shank where it meets the stem. The bowl was heavily caked and the finish was dirty and faded. There was a deep divot out of the left side of the bowl toward the bottom. It was a chipped out spot that looked like the pipe had been knocked hard against something when it was dropped. There was also a chip on the edge of the front right side of the outer rim. It is pictured below in the first photo and is the first pipe in column one on the left. The second photo shows the state of the bowl when I started working on it. The cake was hard and thick.

I sorted through my box of stems and found a wide oval stem blank that would fit the curves and width of the shank. The first photo below shows the new stem before any work was done on it. The second photo below shows the tenon being turned on the PIMO tenon turning tool. I removed enough material from the tenon to get it close to fitting. I hand sanded it to get a snug fit in the shank. The tenon turner literally peels the vulcanite back to the right diameter. The third photo below shows the newly turned tenon before the hand sanding to fit it in the shank. The fourth photo shows the fit of tenon. It still needed to be shaped to match the diameter of the shank but the fit was good and tight.

I removed the excess of vulcanite and shaped the stem close to the diameter of the shank with a Dremel with a sanding drum. I carefully worked the drum against the stem and worked to get it as close to the shank shape as possible without damaging the shank. Once I had it close I worked on the fit with emery paper to remove the marks left by the sanding drum. The next series of four photos show the shaping of the stem to fit the shank with the Dremel and the emery paper.

I reamed the bowl with a PipNet reamer. I started with the smallest head on the T handle and worked my way up to the largest head that would fit the bowl. The next series of three photos shows the reaming of the bowl and the finished reamed bowl.

I cleaned out the divot on the side of the bowl with a dental pick and then packed in briar dust with a dental pick and added drops of super glue. I created a briar dust and super glue fill for the divot. The next series of five photos show the progress of the patch. Once it was filled and even with the surrounding area I used a dental pick to scratch in grooves and crevices to match the sand blasted finish of the surrounding bowl. I wiped down the surface with Everclear and scratched the surface until the finish matched.

I wiped down the entire bowl with acetone on a cotton pad to clean up the finish on the bowl and prepare if for the new stain that I would add once the surface was clean. Note how well the patch on the left side of the bowl matched the grain of the sand blast on the rest of the bowl in first photo below.

I chose to restain the bowl with a dark brown aniline stain that I thinned with two parts isopropyl alcohol to one part stain. From experimenting I had found that this colour matched the original stain on the bowl. I heated the bowl with a heat gun, applied the stain, flamed it and stained and flamed it a second time. I put more stain on the shank near the stem as the smoother portion of the finish seemed to not hold the stain as well as the blasted areas. There had also been a black under stain on the bowl from the original and the thinned dark brown worked well with that under stain to give some depth to the finish of the bowl. I hand buffed the bowl with a shoe brush to give it the initial shine.

I sanded the stem with micromesh sanding pads from 1500-12,000 grit to polish the stem. Each successive grit of micromesh deepened the shine of the stem. Between the 2400 and the 3200 grit micromesh I polished the stem with Maguiar’s Scratch X2.0 – a plastic polish that I have used to polish stems. I then sanded with the remaining grits of micromesh.

After sanding, I buffed the bowl and stem on the buffer with White Diamond and then gave the stem several coats of carnauba wax on the buffing wheel. I used Halcyon II wax on the sandblasted finish on the bowl and shank. I finished the pipe by buffing it with a clean flannel buff to raise the shine of the wax. The finished pipe is pictured below.

The final photo below shows the repaired divot on the bowl. It is utterly merged in the side of the bowl and the finish and stain make it invisible.

Restoring and Reclaiming a Byford Prince

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I was gifted three old pipes by a friend on Smokers Forums. The first that caught my attention was an older Byford Prince. It was pretty worn but the wood was in good shape under the wear and tear. The stem was shot. It had a split along the stop side and was missing a few pieces. When I removed it I found that it was quite brittle. Once I took the stem off I found the most interesting system inside. The shank had an aluminum attachment which held two metal tubes inside of it. On the inside of the broken stem was a third metal tube. These formed three concentric, nested circles which wicked out the moisture of the smoke while not hampering the flow of air in the pipe from bowl to button. The photo below shows magnified picture of the interior of the stem and shank.

The stem was so broken and damaged that I was not sure how the flow of the angles on the taper was supposed to look. I did not know what the button and the stem were supposed to be like. I did a search on the internet and found this photo of a Byford stem that showed the proper angles on the stem. I used the stem in the photo as a template for my replacement stem. I made one modification which I will speak about in the explanation of the restemming below.

The next photo shows the interior of the stem and shank – the system part of the pipe. The tube in the stem sits between the other two tubes in the shank creating three rings on the inside of the shank and stem. It looked like this stem apparatus would be a bear to clean up. I would have to used cotton swabs, folded pipe cleaners and whatever I could to get in between the layers.

The bowl was badly caked with a broken cake. It was soft rather than hard. There was also a buildup of some blue substance on the bowl. I am not sure what it was but it smelled suspiciously like a mold. The stem as you can see in the poor quality pictures below was damaged beyond repair. The aluminum band or shank end was oxidized and rough. Underneath all of the grime it was a beautiful piece of briar. The shape is a well executed prince. The old stem seemed a bit long to my liking so the new one would be slightly shorter and accommodate the lines of the one in the photo.

I removed the old stem and went through my box of stem and found what I was looking for. The drilling on this had to be very wide to accommodate the apparatus on the system of the Byford pictured above. This older style stem had exactly the right fit. It slipped into place and looked good. It was a bit flared on each side and on the top and bottom so that would need to be sanded back to a flush angle. In the photo below you can see the fit of the new stem before I did any shaping on it. You can also see the blue/green substance on the bowl.

I used a Dremel with a sanding drum to remove the excess vulcanite and shape the stem to the proper angles. I reamed the bowl with a PipNet reamer starting with the smallest head and working up to the third head which took the cake back to bare wood. I wanted to remove the cake and whatever the buildup on the bowl and rim that was there.

After reaming the bowl back I sanded the rim and inner edge with a fine grit sanding sponge to remove the remaining blue/green substance. I also sanded the inside of the bowl smooth to remove any thing that was buildup on the inside edges. I sanded the stem with 220 grit sandpaper to remove the scratches caused by the Dremel and sanding drum. I sanded the exterior of the bowl and the oxidized aluminum on the shank end with the fine grit sanding sponge as well. The next three photos below show the state of the bowl and stem at this point in the process.

I wiped the bowl down with an acetone wetted cotton pad to remove the grime and the old finish. The next two photos show the bowl at this point. The cotton pad is below the bowl to show the amount of finish and grime that came off. I find that the acetone will even out the finish and clean up any remaining grime.

I continued to sand the stem with 220 grit sandpaper and also cleaned out the shank apparatus with Everclear and cotton swabs. That was a challenge! The grime that built up in the concentric tubes took some bends and twists of cotton swabs and pipe cleaners to remove from the shank. I also scrubbed down the interior of the bowl with Everclear on the cotton swabs and then scoured it out with 0000 steel wool. I did not want any remnants of the blue/green stuff. While the bowl was wet with the alcohol I also flamed the inside with a lighter. The alcohol burns quickly and should destroy whatever remnants of the sludge that may have been resident in the briar. I sanded the aluminum with 1500 grit micromesh sanding pads to remove the oxidation and crust that had built up at the junction of the aluminum and the briar.

The next two photos show the stem after the pipe and stem have been cleaned and after I had finished shaping the stem with the 220 grit and 340 grit sandpaper. The angles matched the photo above that I was trying to duplicate.

At this point it was time to sand with the micromesh sanding pads. The next series of five photos show the progressive shine that comes through the micromesh. I wet sanded with 1500 and 1800 grit micromesh to remove the scratches and begin to give the stem a polish. I also sanded the bowl with these two grits as well. I followed up by dry sanding with the remaining grits of micromesh from 2400-12,000. I sanded the bowl, the aluminum shank end and the stem.

Upon completing the sanding and polishing with the micromesh pads I took the pipe to the buffer and buffed the stem and bowl with White Diamond on the wheel. It brought out the shine and help highlight the grain. I wiped down the stem with Obsidian Oil to protect it and then gave the entire pipe several coats of carnauba wax and buffed it to a shine. The last series of four photos show the finished pipe.

ADDENDUM 03/07/15
Just recently I discovered this interesting piece on the Byford pipes. They were originally made by Orlik. Here is a page from their catalogue.

Restemming and Reclaiming an Old, Unsmoked Rex Bulldog

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This is the second of the old unsmoked pipe bowls I picked up on EBay. It is one that I can find absolutely no information on anywhere. Some have thought it was a Barclay Rex but I can find nothing that would link it to that shop in NYC. It is stamped Rex in cursive script on the right side of the shank and also stamped Rex over Sterling on the band. It has the look and feel of an older English-made pipe. But I am not sure. The seller said it was from the late 1800’s but all attempts to contact them on the source of that information have remained unanswered. So it remains a bit of a mystery to me. It is one though that I will continue to hunt down until I can come up with something. This shape is what is called in some of the older catalogues a Bulldog. I personally am not sure what to call it. It has the shape of a bulldog on the bowl and the double ring separating the bottom of the bowl from the cap. The shank however, is oval. It has a factory installed band on it that is also stamped Rex. The script on the shank is in gold leaf. The bowl is very clean. There was a small crack in the shank on the shank at about one o’clock looking toward the bowl. This may have been the reason for the band or the band may have been decorative. There was no stem with this pipe so I was not sure of the length of the stem to make for it. The drilling is very interesting. It is drilled like some of the calabash bowls or bowls that were screwed onto Bakelite shank and bases in the late 1800s. It is directly in the bottom of the bowl and seems to have a small hollow chamber under the hole. The airway meets it directly underneath. I have not seen this drilling on briar pipes of newer eras. The bowl is smooth inside and almost polished. The briar is quite nice and sports mixed grains from cross grain to birdseye to flame around the bowl. The double cut rings are clean and are not clogged with wax or dirt. There appears to be a thin coat of shellac on the outside of the bowl to give it a shine as it shines with or without the application of wax. The silver band is interestingly shaped as well. It is somewhat conical – wider toward the bowl side and narrower on the stem side. There is also a stepped down lip on both sides of the band. Where it is on the bowl is stepped down to a small ring around the shank. On the stem side it is also stepped down. This would make fitting a stem to the shank a challenge. It was not too badly oxidized so it would clean up very easily. The first series of five photos are those taken by the Ebay seller and give a good idea of the look and condition of the pipe. The one thing not clear to me was the size of the pipe. I took a chance on it as the apparent age and the assumed age stated by the seller made the likelihood of it being smaller was very high. When it arrived it was indeed quite small. The bowl and shank are roughly 3 inches long without the stem. The height of the bowl is 1 5/8 inches. The inside diameter of the bowl is ¾ inches and the outside diameter is 1 ¼ inches.

Once I started working on it the first decision that needed to be made was on the type and length of the stem to be used. I fitted several oval stems to the bowl – a standard length billiard type stem, a thicker and a thinner oval Canadian stem and a Lovat style saddle stem. The longer stem did not work well with the longer shank on the pipe. The thicker Canadian stem also made the stem look quite chunky and large as did the saddle stem of the Lovat. The stem I settled on was the thinner Canadian oval. Even this one would require considerable thinning to make for a proper fit against the bevel of the band. The first photo below shows the two Canadian taper style oval stems. I chose the bottom stem in the photo.

I used the PIMO tenon turning tool to turn the tenon so that it would fit in the shank. The next three photos show the initial fit of the stem. You will note in the photos the gap where the bevel of the band lies. I had to make a decision to either leave the gap or work on the stem size so that it fit against the bevel and thus was slightly thinner than the shank prior to the band.

I decided to thin the stem to fit against the bevel. I used the Dremel with a sanding drum to bring it close to the finished size. I then sanded it with medium grit emery paper to smooth out the scratches and grooves from the Dremel. Once I had most of the scratches removed I sanded it with a medium grit sanding sponge to further shape the stem and remove excess material. The next series of three photos show the fit of the stem after it was sanded with the sanding sponge (pink square in the photos).

At this point in the process I had to take it back and sand off some more material with 340 grit sandpaper. It still was too thick to fit well. I also had to finesse the fit against the band with needle files as in some places it was not quite straight. When I had it fitting well I moved on to sanding with a 1500 grit micromesh sanding pad (the next two photos). I also did a small repair on the crack in the top of the shank. I pried it open slightly and dripped some clear super glue into the crack. It did not go all the way through into the shank which was interesting. It seemed to be a surface crack. The repair worked well. I polished that portion of the shank with the 1500 grit micromesh sanding pad as well to remove the slight excess of glue left behind (third photo below).

After the repair I continued sanding and polishing the stem with 1800-12,000 grit micromesh sanding pads. The next four photos highlight the sanding/polishing process. Notice the slight hip on the stem at the band edge. In the photos this appears to be more drastic than it is in actual life. The fit is more of a pinched look.

The final series of four photos show the finished pipe. I buffed it with White Diamond and then gave it multiple coats of carnauba wax. I really like the stem and fit against this long shanked “Bulldog” bowl. The pipe glows with an age and patina that calls out to be smoked. This is yet another who will soon fulfill the purpose for which it was made.

Restemming and Reclaiming an Older, Unsmoked GFB Briar Calabash

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Blog by Steve Laug

I bought three unsmoked pipe bowls from the same seller on EBay. One of them was a GFB calabash. With the first of this brand I bought a while back I did some digging on the web and found very little information. So this time I did a bit more searching and I was able to get some information on the brand. Many of the links I found through Google took me to others who were looking for information on the brand. I came across one that gave the information that the GFB brand was an older French Trademark and that it came from Saint Claude, France. With that information I did a more focused search for GFB French Briar Pipes and came across a post that said GFB stood for Great French Briar – that seemed a little farfetched to me so I continued to look and finally came across the following advertisement from a Sears Catalogue. It shows a full page of GFB pipes and the header says GENUINE FRENCH BRIAR. That made much more sense to me and the pipes in the catalogue matched the ones that I have in my collection and the ones that I have seen. For me that gives a better picture into the meaning of the brand letters.

Armed with this new information I went to work on the GFB Calabash pipe bowl that I purchased. The bowl itself was in astonishingly great shape for being over 100 years old. The pipe was unsmoked – new condition. The bowl was dusty but raw briar. The shank was clean and also pristine. This was an unsmoked – new old stock pipe bowl. The silver band was very tarnished and loose. There was no stem to be found. I wrote to the seller and asked what had happened to the stems for this old timer and two others I purchased from them. I did not receive an answer. The first four photos below are the seller’s photos as the pipe appeared on EBay. The first two are out of focus but give an idea of the bowl shape. The last two give close up photos of the stamping and the clean bowl. It was pretty hard to know the size of the pipe from their information. But it looked to be of similar age as an older 1912 BBB Calabash I have so I put in a bid and won.

The right side of the shank is stamped America and the left side is stamped Premier. The band has three stars *** over the GFB in an oval and under that is the Sterling stamp. The stamping led me to assume incorrectly that this was an older American made pipe. I was wrong. The stamping America obviously is the name of the pipe.

I looked through my box of old stems to find one that would be not just a proper fit but of an age that was appropriate to this old pipe. I found one that did not have a tenon, it had either broken or fallen out somewhere along its journey. I have a bag of Delrin threaded tenons that I use regularly for replacing broken tenons. I chose the smallest one as it would fit the mortise with a little bit of work. The stem was oxidized but in good shape with no tooth marks or dents. The button was a slight slot and the stem was quite narrow at the button end. It would look perfect on the pipe once I had the tenon replaced.

I drilled out the stem so that the threaded tenon would fit into it. I used a tap to thread the stem. The first photo below shows the drilled and tapped stem ready to receive the new tenon. I coated the threads with some black super glue and threaded it into the stem (second photo). The third and fourth photos below shows the tenon screwed into place. The tenon is now repaired. I needed to remove some of the Delrin to reduce the diameter of the tenon to get a good fit on the shank. I used my Pimo Tenon turner to do this. It was a little tricky in that the stem was bent but I proceeded slowly to turn it down until it was close. I finished reducing it by hand until it fit snugly in the mortise.

Once the stem fit snugly in the shank I needed to reduce the diameter of the stem in order to get a good match with the band on the shank. I sanded it with medium grit emery paper to bring it down to size. The next two photos show the stem in place. At this point the band had not been glued into place. It was still loose, so I removed the stem and used Weldbond white carpenters glue (which is non-toxic) to glue the band in place. I cleaned up the old glue lines on the shank with micromesh sanding pads.

The next four photos show the silver band after it had been glued in place and cleaned and polished with some Hagerty Tarnish Preventive Silver Polish. I have used this bottle for years and it works extremely well. I purchased it at a jewelry shop along with a polishing cloth that I used on the band as well. Once the band was polished the hallmarks were very visible. I have described the stamping on the band above. After shining they stood out clearly. I am not able to ascertain a date from the stamping as there are no date stamps. I also polished the bowl with a quick buff of White Diamond on the buffer and then I gave it multiple coats of carnauba wax.

With the bowl and band finished it was time to work on the stem. I sanded it with 220 and 340 grit sandpaper followed by sanding with a medium grit sanding sponge and then a fine grit sanding sponge. This series of sandpapers and sanding sponges has worked well for me in removing the scratches left by the emery paper as well as the remaining oxidation on the stem. I then sanded the stem with micromesh sanding pads from 1500-12,000 grit to bring out the sheen on the stem and polish it. Between the 4000 and the 6000 grit I polished the stem with Maguiar’s Scratch X2.0 plastic polish. I finished with the last grits of micromesh sanding pads. The next series of six photos show the progressive shine on the stem with the various grits of micromesh.

I buffed the stem and bowl with White Diamond and then gave the pipe several coats of carnauba wax. The finished pipe is pictured below in the last series of four photos. It is amazing that this old pipe has existed this long since it was made and has not been smoked. That will change soon!

A New Pipe Born from a Pre-drilled Block

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I purchased a pre-drilled block of briar with a Lucite stem from Burlington on Whyte Tobacconist in Edmonton a few weeks ago. I sorted through the box of blocks they had at the shop and chose this one. It showed some interesting birdseye grain on the sides and some straight grain on the front and back. I also like the angle of the stem on it and figured it might be an interesting project to work on between some of the refurbs that I have going all the time. I put it on my desk in my basement office next to the computer keyboard and looked at pretty much daily trying to figure out a shape that would fit the grain and the angles of the block. I used pencil and scribbled a lot of them on the block, erasing and reshaping the image repeatedly until I finally saw a shape that I kind of liked and figured I could carve it easily enough.

I used a blunt pencil and sketched the rough idea on the block. I have carved enough to know that what the original sketch looked like may be far removed from the finished pipe. As the excess briar was removed there would likely be flaws that would change the shape of the finished pipe until it became quite different from the original concept in my mind. Also I have learned that the height of the bowl can also dramatically change as I carve into the block. But at least I had an idea and was ready to begin the carving. The next series of five photos show the block after I removed the surface material to get a look at the grain. After sketching the drawing on the block I took it into the back yard and began to remove briar from the block with my Dremel and a large sanding drum.

The next four photos show the block after the initial work with the sanding drum. I removed all of the square edges and the excess height of the block and began the rough shaping of the new pipe concept. The grain is actually going to be quite nice as far as I can see at this point. There were also some flaws showing up in the block on the left side near the shank bowl junction and also on the bottom edge of the left side of the bowl. These are visible in the first photo and look like a line across the bottom edge. At this point I brought the block inside and took the photos below before taking it back out to work on rounding out the edges of the bowl and shank.

I took it back outside and used the Dremel and sanding drum to remove the edges and begin to round out the bowl shape. At this point I was not aiming for smoothness only rough shape. The next three photos show the bowl after this shaping was completed. You will note that the inside edge of the shank bowl junction is quite rough. I took a lot of briar off at this point to lengthen the shank and to clean up that junction. A lot more work would have to be done but the shape was beginning to show more clearly. The flaw at the bottom of the left side of the bowl and shank was actually becoming bigger and are visible in the first picture as a darkened line at the bottom of the bowl and shank. I apologize for the lack of clarity in these photos but it was late evening at this point and I did a poor job of focusing.

From this point in the process I used files and wood rasps to remove more of the briar and to refine the shape of the bowl. I also decided to cut the stem into a saddle bit as I thought that look would go well with the shape I was working on. The pipe was becoming a modified egg shape. Where it would go from here would be worked out with the files and the work at removing the flaws in the briar as much as possible. The next four photos show the shaping of the saddle stem with the wrasp and files.

Once I had the rough shape on the stem I used the files and rasp on the bowl of the pipe. I filed away the briar to further round out the shape of the bowl and shank. The flaw in the shank and bowl bottom on the left was still an issue that would take a lot more work to see if I could remedy it or work around it. The next five photos show the rounding of the bowl after working it over with the files and rasp.

After using the files I sanded the bowl with coarse grit emery paper to further shape the bowl, shank and stem. I worked on the shank to round it out and match the diameter of the stem. The next four photos show how far the shape has come to this point. The flaw is also very visible in the first and the fourth photos below. It is very deep at some points and on the surface in others. It does not go into the interior of the bowl or shank so there will be a lot more sanding to see if I can rid the block of the flaws. To me this is always one of the surprises that lie within a block of briar. They never become visible until a lot of work has been done in shaping. At this point I was wondering if I would need to rusticate the bowl or possibly figure out another option or shape to deal with the flaw.

I continued sanding the bowl with the emery paper and then switched to a coarse grit sanding sponge. At this point I was not worried about scratches that would come later. I only wanted to remove more of the briar. I also heated the stem with my heat gun and bent it to shape. I still needed to clean up the junction of the shank and bowl. It needed a little less slope in my opinion. The next three photos show where things were at this point in the process. The pipe is beginning to take shape. I have also removed quite a bit of the briar around the flaws on the bottom edge. The change can be seen in the first photo below.

I used the files and rasp to remove more of the slope on the back side of the bowl and make the angle more in tune with the front slope of the bowl. Once I had removed what I wanted I used my sanding sponge and the emery paper to remove the marks of the files. With removing more of the slope I also decided to define the curve of the back side of the bowl along the shank and make the angle there more obvious and distinct. I used the Dremel with the sanding drum to shape this portion of the bowl on both sides. The beauty of this decision is that it removed a fair piece of the flaw in the shank and bowl. The next three photos show the shape after I worked on defining the angles more clearly. The question in my mind at this point was whether I would be able to make the stem as thin as I would like due to the deeply set tenon in the stem. Nonetheless the finished shape of the pipe emerging from the briar.

The next series of three photos show the bowl after I had sanded it with 220 grit sandpaper. I gave it a quick coat of medium brown aniline stain and flamed it. I buffed it with White Diamond to see where things stood at this point. The grain was very clear on the sides – some nice birdseye on the right side of the bowl, cross grain on the front and back of the bowl and on the top and bottom of the shank. The left side of the bowl was mixed grain toward the bottom and the flaws were glaring. The top half of the left side was covered in birdseye. The top of the rim was cross grain that matched the top of the shank. The stem was bothering me at this point so after taking the photos below I fit a vulcanite stem to the shank. I like the flow and the thinness of the stem. I made the decision to keep the vulcanite stem and put aside the Lucite one.

With the new stem in place I sanded the shank and stem to match cleanly. I also continued to sand the bowl and shank with 220 grit and 340 grit sandpaper. I also used a fine grit sanding sponge on the bowl. Once the visible scratches were gone I took it outside into natural light to inspect for further scratches. I took it back to the work table and wet sanded it with 1500 and 1800 grit micromesh sanding pads. I continued sanding the bowl and shank with 2400-12,000 grit micromesh until the bowl was smooth. I examined it under a bright light and reworked the places where there were still minute scratches. Once that was done I decided to stain the bowl.

I wanted to try something different with the staining process this time around so I first gave it a coat of black aniline stain and flamed it. Once it was dry I sanded and buffed the bowl with Tripoli to remove the stain from the surface. My purpose was to highlight the grain in the briar and make it more visible. The black was to be the first undercoat of stain that I would use on this pipe. The next three photos show the black stain after much of it has been removed. The grain is very visible in the photos. The birdseye and cross grain really stand out. After these photos I wiped the bowl down with a cotton pad wet in Everclear to remove more of the surface stain and prepare the surface for the next coat of stain.

The second coat of stain that I used was an oxblood stain. I applied it with a bent pipe cleaner, flamed it. Once it was dry I polished it by hand with a terry cloth to even out the finish and make sure it would be ready for the next coat of stain (photos 1 and 2 below). I took it to the buffer and buffed it with White Diamond and then gave it a coat of Dark Brown aniline stain thinned 2:1 with Isopropyl alcohol. I flamed the stain and then buffed it again with White Diamond. Photos 3 and 4 show the pipe after that work. The grain is really standing out now and I am pleased with the finished colour of the pipe. It is a rich reddish brown in colour and will deepen once I have waxed it and polished it. The beauty of this combination of stains is that it really served well to blend in the flaws in the briar on the bottom left side. They are still there but are less glaring.

With the staining finished it was time to do more work on the stem. I sanded out the scratches that remain with 340 grit sandpaper and then a fine grit sanding sponge. I worked on the angles of the saddle with the sandpaper and sponge to clean up the cut marks in the vulcanite. I continued wet sanding the stem with 1500-2400 grit micromesh sanding pads and then polished it with Scratch X plastic polish to remove the remaining scratches. The next series of nine photos shows the bowl finish after 4 coats of carnauba wax and a buff with a soft flannel buffing pad. The finish is actually quite amazing and the grain made this work keeping smooth even with the visible flaws in the briar. The stain masks the flaws and blends them into the black of the grain well and though they are present they are not glaring. The stem still needs more work at the point of these photos but it is beginning to take on a shine.

The final four photos show the finished pipe. I continued to wet sand the stem with the 1500-1800 grit micromesh sanding pads until the scratches and rough areas were clean and black. I then dry sanded with the remaining grits of micromesh from 2400-12,000 to polish the stem and give it a mirror like finish. Once that was finished I waxed the pipe and stem several more times with carnauba wax. All that remains is for the pipe to be christened with its first bowl!

Can a Cracked Bowl be Repaired? – Taking a Lesson from Gan Barber’s Work

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Blog by Steve Laug

Many of you have read the piece that Gan wrote on “All the King’s Horses and All the King’s Men – A Peterson Adventure” https://rebornpipes.wordpress.com/2012/10/03/all-the-kings-horses-and-all-the-kings-men-a-petersen-adventure-gan-barber/ In it he described the process of reconstructing a Peterson that was in pieces. It arrived with cracks and he put the pieces back together. Since interacting with Gan on that pipe and rereading his article I have wanted to try my hand at repairing a cracked bowl. Finally I picked one up in an EBay lot that I purchased. It was an L. J. Perretti Smooth Bent Billiard. It was in rough shape and needed a stem. I figured I would practice some of the magic Gan used on the Peterson pipe he wrote about on this one.

This Perretti had some deep cracks that ran through the bowl from outside to the inside. Once I had reamed the extremely thick cake out of the bowl I could see that the cracks went all the way through the briar. There were deep gouged areas on the inner walls of the bowl directly behind the cracks. The wood was not charred so it was not a true burnout. I think that a combination of too thick a cake and possible flaws in the briar made these cracks appear. Interestingly the cracks follow the grain all the way through the pipe. I shined a light through the cracks and I could see light on the opposite wall of the pipe bowl. There were two large cracks on the left side and one running with the grain on the front of the bowl. The one on the front was not as open and it did not go all the way through the briar. The ones on the left side were quite open and cavernous.

The first series of seven photos shows the state of the bowl when I began the experiment. I figured I had nothing to lose on this one. If it fell apart or did not work out it was not a great loss at all, but it would fun giving it a try. I wanted to try out some of the methods that Gan used in his reconstruction of the Pete on this one and see what I could do with it.

After reaming thick cake back to the bare wood I sanded the exterior with 240 grit sandpaper to clean off the finish and get a better look at the nature and depth of the cracks. I wanted to be able to more clearly see how far across the bowl they stretched and if the cracks followed the grain. I had already seen the state of the inside bowl walls. The left side interior showed damage from the crack extending into the bowl. The front side was less damaged. It had some very minor cracks on the inside walls. I blew air through the shank into the bowl and plugged the top of the bowl to see where the air came through the walls. The only one that really allowed airflow was the larger crack on the left side toward the front of the bowl. The next three photos show the sanded bowl. I left sanding dust in the cracks to highlight their depth and the extent of damage.

I decided to put the bowl in the alcohol bath. I wanted to soften the remaining cake in the cracks and crevices inside the bowl and also soften the grime within the cracks. I had no idea what would happen to the bowl as it soaked. I almost expected it to come out of the bath in several pieces. I got busy with work and other demands and ended up leaving it in the bath for over 24 hours. When I finally removed it and let it dry for several days I figured that the drying would probably make the cracks worse.

When I removed the bowl from the bath it was not in pieces but the cracks did open a bit wider on the side of the bowl. The finish and grime was gone and I could clearly see what I had to do if I was going to repair this bowl. The end of the shank had also been damage and chipped so I decided to band it to give me a smooth edge for the new stem I was going to turn for it. I used a nickel band, heated it with the heat gun and pressure fit it on the shank of the pipe. The one bonus in the process was that the grain on this pipe was actually quite nice. The next three photos show the dried and banded bowl and shank. There was still a lot of sanding that would need to be done to prepare the bowl for the repairs and even more sanding once those were done.

I selected a stem that had the same diameter as the shank and turned the tenon on the Pimo Tenon Tool. I finished the fit by hand with a little help from the sanding drum on the Dremel. Once I had a good fit I set up the heat gun and heated the stem to bend it to match the bend of the bowl and bring the tip even with the top of the bowl. The next three photos show the heating and bending process as well as the finished look of the pipe with its new stem.

After I restemmed the pipe I did some more sanding on the bowl. I wanted a clean surface to work with when I did the patches on the cracks. I also cleaned out the inside of the bowl with sandpaper and a dental pick. I wanted to clean out the interior cracks in the bowl as well as the exterior ones. Each would use a different kind of patch but each needed a clean surface to work with. The next five photos show the cleaned exterior of the pipe and two photos of the interior. Still more work needed to be done to clean them up before I patched them.

For the exterior cracks I decided to use a patch mix of briar dust and superglue. I cleaned the cracks out with my dental pick and some Everclear. Once they were clean I packed them with briar dust, tamping it into the cracks with both the flat head of a tamper and also the tip of the dental pick. Once they were filled the first time I dripped the superglue into the cracks. The glue binds the dust and the surrounding briar and also compacts the briar dust. I then retamped in some more briar dust and repeated the process until it was filled. The next six photos show the process of filling the cracks around the bowl.

Once all the cracks were filled I sanded the bowl with 240 grit sandpaper to remove the excess material on the surface of the bowl. You will note the scratches in the surface of the briar. These would be removed in the successive sanding that still would be done to the bowl. The cracks are filled and the surface hard. The briar dust and superglue form a good bond with the crack and when dry are dark black in colour. They are hard to the touch even with the dental pick. The next four photos show the bowl after sanding. The surface is smooth to the touch.

The scratches on the bowl have been minimized with the fine grit sanding sponge pictured above. I continued to sand until the marks were gone using 320 grit sandpaper. Once I had the bowl to that point I wiped it down with Everclear on a cotton pad. The three photos below show the bowl after the wash.

I continued to sand the bowl with micromesh sanding pads from 1500-12,000 grit to smooth out the surface of the bowl. The micromesh left the surface ready to be stained. The cracks are still visible in terms of the black lines but the cavernous gaps are filled and repaired.

I decided to stain the bowl with a rich oxblood aniline paste stain. I applied it to the bowl, flamed it and applied it a second time and flamed it. Once it was dry I wiped it off and hand buffed the surface. My purpose was not to hide the flaws but to minimize the glaring nature of the repairs. The next six photos show the staining and rubbed down bowl. I was not happy with the coverage but I buffed it quickly with White Diamond to see what I had to work with. The final photos in the series of six show the buffed and polished look of the bowl.

I decided to give the bowl a second staining of a dark brown aniline colour. This was a mix of dark brown and alcohol 1:1. I applied it and flamed it. I repeated the process to darken the colour of the bowl. The four photos below show the result of the application of the brown stain.

After the stain had dried it was time to address the inside of the bowl. I sanded it out quickly with a Dremel with a sanding drum attachment. I was careful not to change the shape of the bowl but to merely remove any carbon cake that still remained. I wiped the inside down with Everclear and then flamed it to dry out the surface of any moisture. I then mixed a batch of JB Weld. This would be the first step in doing the interior repairs. I packed it into the cracks on the inside of the bowl using the spoon end of the pipe nail. I continue to pack it into the bowl cracks until they were smooth. The four photos below show the mix and the patch in the bowl. It has a drying time of 6 hours to dry to touch and 24 hours to cure.

While the bowl was drying I worked on the new stem. I sanded down the castings on the side of the stem and polished it with micromesh sanding pads. I used 1500-12,000 grit micromesh pads on the stem. I pictured three photos below to show the process.

The next series of eight photos show the patch after it had dried. I also reapplied the JB Weld after the initial 12 hours so that it filled in the places where it had shrunk as it dried. The patch dried a fine grey coloured. I sanded it down until it was only in the cracks themselves and not in the clean briar. I wanted to give the briar as much absorption area as possible as the JB Weld does not absorb moisture at all. It dries to a neutral, hard metallic material that has no taste.

Once the JB Weld was cleaned up and reduced to only filling the cracks it was time for the second step of the bowl interior renewal. I mixed a batch of bowl coating composed of activated charcoal powder and sour cream. I stirred the batch until it was a consistent blue/black grey colour. I applied it to the entire bowl from top to bottom with a folded pipe cleaner. Once it dries it is a solid black colour and neutral in taste. It gives the bowl an additional layer of protection until the cake builds up. The next three photos show the mix and the application in the bowl.

With that done, both the inside and the outside cracks are repaired and the pipe is back in service. I gave the entire pipe a final buff with White Diamond and then applied multiple coats of carnauba wax for protection. The final photos below give you an idea of how the pipe looks today. It is still curing from the bowl coating but I will load it and smoke it once that has cured. The finish of the two stains worked well to blend in the repairs but not hide them. The surface is smooth and the open cracks have been repaired. Now the ongoing test begins. Will the patches hold up or will the new heat from the fired tobacco open them a second time? Time will tell but it is worth the experiment in my opinion.

A Renewed WDC Bakelite and Briar Pipe Restemmed

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I received the Bakelite bowl base in a lot that I picked up on EBay. At first glance I figured I would trash it and not worry about working on it at all. However, I tend to be drawn to working on things that others would throw away so I decided to see what I could do with it. The two bowls pictured below are threaded and both fit the base. The Dublin like bowl, once on the base, was too narrow for the base but the bulldog bowl fit well. It was packed with a cake and there were chips out of the double line band around the bowl. The bowl rim was damaged and the finish was absolutely shot with dark black stains in the briar all around the bowl where the thumb and fingers held the bowl. The Bakelite shank had the WDC in a diamond stamped on it. The ornate band that usually adorned the shank as well as the metal washer like band on the top of the bowl base was missing. The shank had a broken metal tenon stuck deep within it. The surface had scratches in it but none of them were too deep.

Bakelite bowl base and two potential bowls before beginning the process of refurbishing.

The bowl is pictured below. You can see the thickness of the cake and the rough surface of the rim where a previous owner had damaged it when emptying the bowl. The second photo shows the exterior damage and the finish on the pipe. I reamed the bowl to clean out the cake. I decided to take it back to bare wood and start over with the cake. I checked the bowl for cracks and damage but surprisingly there were none to be found. Eventually I would top the bowl.

SIde view of the bowl before refurbishing.

Top view of the unreamed pipe bowl showing its condition before cleaning

I wiped the bowl down with acetone on a cotton pad, used a dental pick to clean out the grooves and screwed bowl on the base to get an idea how the pipe would look. I also wiped down the bowl base with Everclear to clean off the grime and buildup on that surface. I went through my can of stems in search of a diamond shaped stem that would finish out the look of the pipe. I came up empty-handed so I chose a round stem of the right diameter and length that I could shape to fit the shank. I drilled out the shank to remove the metal tenon and also to open the diameter of the mortise. The original stem had been a screw on one and the metal mortise and the metal tenon were firmly welded together so the drill was the only way to remove it. I opened it as wide as possible while still leaving enough material on the shank to maintain strength. I turned the tenon with the PIMO tenon turning tool and then a Dremel to bring it to the correct size for the new shank. The next two photos show the stem and the fit of the stem to the shank.

WDC base in need of a diamond shaped stem. Necessity is the mother of invention. I used a round Lovat stem.

I turned the tenon to fit the mortise and then inserted the stem against the shank.

Now I needed to shape the stem and remove material to transform the round saddle bit to a diamond saddle bit. I used a Dremel to cut the basic shape in the stem. I proceeded from side to side with the stem on the shank to make sure to match the angles of the shank. I wrote a post on the process for the blog and posted that earlier. You can read about the details of that process on this link https://rebornpipes.wordpress.com/2013/04/15/shaping-a-diamond-shaped-stem-from-a-round-one/ The next eleven photos give a quick look at the shaping work on the stem. It took time and I had to be careful to not damage the shank when I was using the Dremel and sanding drum on the stem.

Figure 3 I used a Dremel to shape the stem to match the diamond angles of the shank. I worked on one side at a time.

Figure 4 Pipe resting against the Dremel with a sanding drum. Shaping progressed quite quickly. This picture shows one side beginning to take shape.

5 Top view of the shank. Both sides of the round stem are beginning to take on the shape of the shank.

Figure 6 Top view after more shaping with the Dremel.

Figure 7 Bottom view before the Dremel did its work.

Figure 8 Left side view after the first side has begun to take shape.

Figure 9 Bottom view after both sides have begun to take shape.

Figure 10 Right side view of the stem after it began to take shape.

Figure 11 Back to the worktable and the hand sanding.

Figure 12 Hand sanding continues.

Figure 13 Hand sanding continues.

The original shank had sported an ornate band and the stain in the Bakelite showed the marks of the band. I did not have any ornate bands in my collection of bands so I chose instead to band it with a nickel band. I shaped the band to fit, beginning with a round band. This took a bit of fussing to get the shape and fit correct. I have written that process up in detail in a previous blog post as well. You can read about the process at this link https://rebornpipes.wordpress.com/2013/04/15/shaping-a-round-metal-band-to-fit-a-square-or-diamond-shank/ Once the band was shaped correctly I heated it with a heat gun until it was pliable and then pressure fit it on the shank of the pipe. The next series of five photos show the process I used to pressure fit the band on the shank. Once it was in place I carefully used my furniture hammer to flatten the band against the shank.

The square is done

Fitting a nickel band on the shank

Nickel band fitted on the shank

The next series of four photos show the newly shaped stem in place on the banded pipe. There was still a lot of work to do on the pipe including cleaning the internals and reworking the bowl and rim but the overall look of the “new” pipe is intriguing.

New band and stem in place.

New band and stem in place

Bottom view of the newly banded and stemmed pipe

Top view of the new band and stem

I have included one photo below to give you an idea of the shape of the new stem. I remove a lot of vulcanite to get it from its original round shape to the diamond shape pictured below. The fit and the angles match the shank perfectly. These older pipes are tricky to fit a diamond stem on because none of the sides of the diamond are the same dimensions. Each one is just slightly different so you have to do the fitting work with the stem in place on the shank.

View from the tenon end of the diamond stem at this point in the process.

With the stem fitting correctly it was time to tackle the bowl. I set up my board and emery paper so that I could top the bowl. The first photo shows the set up. The second photo shows the state of the bowl rim when I started the process.

Set up for topping the bowl

Reamed and ready to top

Once I had it topped I decided to wipe it down with acetone on a cotton pad to remove the finish and the grime from the topping. The next three photos show the clean bowl and the topped bowl. The finish work would take some time but the bowl was ready to move on to the next stage of rejuvenation.

Wiping down the bowl with acetone

Wiping down the newly topped rim with acetone

Wiping down the bowl with acetone

I sanded the bowl with 240 and 320 grit sandpaper and finished sanding with a fine grit sanding sponge. The next two photos show the cleaned and prepped bowl ready for staining. The dark oil stains on the sides of the bowl would not come out. I wiped the bowl down with repeated washings of acetone and the surface was clean. I also sanded the stem with the sanding sponge while I worked on the bowl.

Bowl sanded, in place and ready to stain.

Bowl in place, sanded and ready to stain.

I decided to restain this old timer with an opaque oxblood aniline based stain. I wanted the opacity so that the dark stains would be minimized beneath the new stain and would eventually be blended in through smoking the pipe. I applied the stain and then flamed it. After flaming I hand buffed it to remove the excess stain. I also used a cotton pad and a dental pick to clean out the grooves on the bowl.

Stained with oxblood stain.

The next series of four photos shows the hand buffed bowl in place on the pipe base. The finish was matte at this point and still needed to be taken to the buffer to raise the shine. The third photo shows the rim. The surface is smooth but there is still damage to the inner edge of the rim. I chose to leave that without reworking it too much. I did not want to change the roundness of the inner bowl and decided that I could live with the nicks in the inner edge.

Left side of the pipe with a hand buff on the newly stained bowl.

Right side of the newly stained bowl with a hand buffed surface.

Top view of the hand buffed newly stained bowl.

View of the underside of the bowl and Bakelite bowl base.

The next three photos show the pipe after I had buffed it with White Diamond. The bowl shines and the dark marks around the bowl show faintly beneath the finish but add a flair of character to the old pipe.

Buffed with White Diamond

The next series of three photos are included to give an idea of the polishing process that went into bringing the stem work to completion. Again I invite you to read the post mentioned above on the transformation of a round saddle stem to a diamond shaped one to understand the full work that the shaping took to bring it to this place.

Stem sanded with 320 grit sandpaper

Stem sanded with micromesh sanding pads

Once I had finished polishing the stem with the various grades of micromesh from 1500-12,000 grit I took the pipe to the buffer once again and buffer the entirety with White Diamond and then gave it multiple coats of carnauba wax to protect it and to give it a deep shine. The next series of four photos show the finished pipe. It is ready to load up with a favourite tobacco and be gently sipped in the solitude of an afternoon on the porch.