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Handle needed for a 35mm knot

I have a 35mm Kabuki brush that I enjoy using as a shaving brush. The base is just the little black plastic cap that these things come with, and I'd love to find something better for a handle. However, since no one makes 35mm knots, none of the artisans I'v talked to have bits to drill that kind of knot bed. Does anyone have any ideas of what I could use for a handle? I'm open to any ideas, even stuff thats a bit out of the box if its all that might work. Thanks for any ideas you all might have.
 
Anyone with a lathe could fix you up easily. I am out of town on business for the next two weeks. When I get back, if you haven't hooked up with someone, I would be happy to do it for you.

Al in colorado
[email protected]
 
Thanks Al! I had talked to most of the usual vendors, its the blank/bit that they dont seem to have. However I might just well take you up on that in two weeks if you have the materials.
 
A two inch diameter piece of material would be about perfect. 35mm is 1 3/8 in. I am pretty sure that I have some stock that size in ebony, mopane, and Birdseye maple. Any woodcraft store or woodworking store that deals in specialty hardwoods will have plenty of other stuff.
you have my email, send me a tickler in a couple weeks.
i can also turn something in aluminum as well.
al in colorado
 
It would be easy to make something along these lines...

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I don't know if he has the bit required for it, but shoot Curt at Fat River Trading (http://www.etsy.com/shop/FatRiverTradingCo) an e-mail. I've worked with him several times, and he's been fantastic.

I recently picked up a gorgeous Osage Orange brush from him - he went and hand-selected a blank to be as orange/pretty as possible.
 

Slash McCoy

I freehand dog rockets
Make a wax model. Cast it in plaster of Paris. Heat it slowly and melt out the wax. Get some polyester resin and hardener from home depot. Mix a mineral coloring agent into the resin like maybe CrOx. Add hardener and mix thoroughly and pour it into the plaster mold. Next day break the plaster away and sand and polish.

Or get a piece of 2x2 oak and a 35mm paddle or spade bit. Drill into the end of the wood. Cut wood to length and shape and sand by hand. Finish with tung oil or linseed oil or superglue.

Or shape wood roughly round. Drill 3/16" hole in center. Twist a 1/4" x 3" wood screw into the hole about 3/4" deep. Cut the head off the screw and chuck it into a variable speed drill. Secure drill to your workbench. Tie the trigger down on slow speed with wire. The drill is now a lathe. Turn it down using 40 grit sandpaper and improvised tools. Bits of SE blade backed up by a screwdriver will work. Finish with a progression of sandpaper and whatever oil or varnish you like. Remove the screw and cut a recess to hold an interesting medallion or coin and glue that in.

More than one way to skin a cat.
 

Rudy Vey

Shaving baby skin and turkey necks
To drill such a large hole should not be a problem. The largest resin blanks my caster makes for me are about 50 mm in diameter, however, with such a huge "knot" the handle also will be quite huge.
 
Haha, I wondered if you'd done something like this yet. I'm already looking at that handle and picturing what that knot would look better in. Really I think a chubby knockoff would be the way to go for these things. Short, stubby and suited for a big, low lofted knot.
 
Thanks for the help everyone. Unfortunately the project is on hold... but only temporarily. After much testing, my 35mm Posh kabuki has started shedding. I think it's my fault as I used HOT water to remove the die that would come out of this brush when its lathered. That and the goat hair used in it does not load soap well, so I was making up for that with extra pressure while loading. Basically I killed the brush. Also, after a talk with Ian, I am not as sure goat hair is good for wet shaving. Loading is a problem, and the hair is so fine that some of the hairs were showing signs of stress.

Fortunately, I have found some other 35mm synthetic Kabuki's to try. I have a couple on order, and if they are what I hope they are, will be looking for a handle in a couple weeks.

Thanks again for all the help!
 
Make a wax model. Cast it in plaster of Paris. Heat it slowly and melt out the wax. Get some polyester resin and hardener from home depot. Mix a mineral coloring agent into the resin like maybe CrOx. Add hardener and mix thoroughly and pour it into the plaster mold. Next day break the plaster away and sand and polish.

Or get a piece of 2x2 oak and a 35mm paddle or spade bit. Drill into the end of the wood. Cut wood to length and shape and sand by hand. Finish with tung oil or linseed oil or superglue.

Or shape wood roughly round. Drill 3/16" hole in center. Twist a 1/4" x 3" wood screw into the hole about 3/4" deep. Cut the head off the screw and chuck it into a variable speed drill. Secure drill to your workbench. Tie the trigger down on slow speed with wire. The drill is now a lathe. Turn it down using 40 grit sandpaper and improvised tools. Bits of SE blade backed up by a screwdriver will work. Finish with a progression of sandpaper and whatever oil or varnish you like. Remove the screw and cut a recess to hold an interesting medallion or coin and glue that in.

More than one way to skin a cat.
This is only slightly easier than your squirrel recipe.
 
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