Thread: Aluminium brush rebuild x 4

Thanks gents. The sensation through the hammer is what controls the impact and I think that needs to be manual to give the control to shape and pocket.
With practice a tube could be easily transformed into a bulbous shape I think. Found it very intuitive and frankly kinda fun. Thanks again for turning me on to the technique Richard.
Now I need to dress the dents back the other way slightly so need a rigid internal form to tap against.
Then, on to the lathe to buff it back out.
Seeing as how they used sawdust not talc to fill this handle I know why all the ones I've seen are dented now. Stuff isn't rigid enough to keep this thin walled stuff dent free over time.
I'm going to fix that by filling the entire thing with alumilite before reknoting. Will be slightly heavier, but impervious to subsequent denting and last another lifetime.

I loved-it! The clawhammer made it work even better!

Originally Posted by MikeB52

Thanks gents. The sensation through the hammer is what controls the impact and I think that needs to be manual to give the control to shape and pocket.
With practice a tube could be easily transformed into a bulbous shape I think. Found it very intuitive and frankly kinda fun. Thanks again for turning me on to the technique Richard.
Now I need to dress the dents back the other way slightly so need a rigid internal form to tap against.
Then, on to the lathe to buff it back out.
Seeing as how they used sawdust not talc to fill this handle I know why all the ones I've seen are dented now. Stuff isn't rigid enough to keep this thin walled stuff dent free over time.
I'm going to fix that by filling the entire thing with alumilite before reknoting. Will be slightly heavier, but impervious to subsequent denting and last another lifetime.

What about just using regular epoxy Mike? Don't waste that good stuff???

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Originally Posted by sharptonn

I loved-it! The clawhammer made it work even better!

Claw hammers always make things go better. A garage staple! Hehe. That's 1's an oldie though Tom. One of my fav's. I could have done that job with my 4 oz ball peen.

And you might be right Andrew, some jb should mix up,hard enough to give it better strength than the squishy sawdust provided. A lot less cake than the alumilite.
Save that $ for the knot,,

Nice job popping the dents out, so cool! Watched the vid first thing this morning. Mike, Richard, that was awe-some! And as a bonus, I let the video play to the end and the next thing I know I have a sky view of frozen Island Lake, beautiful.

Great Job Mike!! And Richard, thanks for passing on your knowledge. It's things like this that are getting lost from generation to generation.

Looking forward to seeing this brush finished. I am still just amazed at how simple and effective that was. But then again, it is the simple things that get a great end result

Really cool Mike. What a great technique to referbish these old handles. Love it.

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Had an idea, and it worked pretty cool, literally.

Filled the handle to just below the neck with water and froze it to create my inner form to reverse dress the dings.

Had to work quickly as the ice started to melt instantly. Tapped it some with the ball peen, then spun it and used a soft wooden paint brush handle to try and blend everything back in with some gentle pressure.


Might be as good as it gets.
All three are measured and it looks like I can stuff 24 mm knots in all three. Think the first rubberset rebuild I did I went 23 mm to be sure.
What do you think Andrew and Tom?
Cheers gents. Hope you had great weekends. Saw lots of cool projects moving along in the various threads.

That's coooool! Icy cool, my friend! I think you've done a tremendous job and some ingenious ideas to get there. I mean, going back and looking at the first picture in this thread to what it is now... remarkable.

Originally Posted by MikeB52

Had an idea, and it worked pretty cool, literally.

Filled the handle to just below the neck with water and froze it to create my inner form to reverse dress the dings.

Had to work quickly as the ice started to melt instantly. Tapped it some with the ball peen, then spun it and used a soft wooden paint brush handle to try and blend everything back in with some gentle pressure.


Might be as good as it gets.
All three are measured and it looks like I can stuff 24 mm knots in all three. Think the first rubberset rebuild I did I went 23 mm to be sure.
What do you think Andrew and Tom?
Cheers gents. Hope you had great weekends. Saw lots of cool projects moving along in the various threads.

You did a smokin' job on the C-MON, when I grabbed it didn't seem that bad, looks brand spankin' new now - great job.

And yes, on the #3 you did for me, we went with the Shavemac D01 knot - 23 x 48.

With the #4, figure the same 23 x 48 and the D01-2 band this time...that way I'll be representin' two styles.....