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A piece of
Black Walnut about 50mm square, the copper collar with beading, and
16 SWG copper sheet to use for the inset "ring".
The first
task was to turn the walnut from square to round on the lathe...
... and then
divide it into three pieces for three shaving brush handles.
The end of
one piece is drilled, and then threaded with a tap
and a small
tenon turned in the end the same diameter as the inside of the
copper collar.
The piece was
then mounted onto my special screw chuck. (I have put some very thin
CA glue into the threads in the wood to give it a bit more
strength).
The cone
shape roughed out
Then I used a
fine toothed Japanese saw to cut off a section of the handle at an
angle.
The piece was
then used to roughly draw the outline of the shape on the thick
copper sheet. The disc was then cut out of the sheet using a
jeweller's saw.
I drilled two
small holes in the copper disc and the wood and then inserted small
pins to help register the disc onto the wood, as well as provide a
little extra strength when the copper was glued to the wood.
CA adhesive
applied to each side of the copper disc and the assembly clamped
together using the tailstock of the lathe to apply pressure.
Most of the waste copper was removed with a
file....
... and then
the cone shape of the handle was turned down. Copper cuts very
easily with normal woodworking lathe tools. The handle is sanded
very smooth down to 2000 grit, which also polishes the
copper....
.... and then
10 coats of acrylic finish added. The acrylic is then sanded down
smooth and polished. This forms a 100% waterproof seal to the
wood.
Finally, the
copper collar is glued onto the small tenon on the top of the walnut
handle.
The 26mm
Super Silvertip Badger hair knot is then glued into the copper
collar.
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