There seems to be quite a few TSDers making their own brushes now. Most seem to be turners using a lathe to make their handles, but others have carved or shaped their unique creations as well. I’ve been thinking of starting a thread to discuss different styles, techniques, tools, finishes, etc. Basically, I think a sharing of ideas around making brushes and other shaving related turnings and carvings can be really interesting and worthwhile. Not for accolades, per se, but so that we can learn from each other.

Here are a number of my own brushes that I have kept:

I’ve experimented with different shapes, but often have a lot of similarities in what I’ve made. I often use paint for effect, and have recently started to experiment with texture, as with the Chubby handle near the right edge above. I have also mixed materials a bit, with some brass ferrules (above) and resin/wood mixes (not shown).
I also made the 30DC LE brushes that are posted on the forum pretty regularly. Mine is above, and I took a family shot of some a few years ago:


As far as techniques- after rounding the stock, I use a four-jawed chuck to secure it below the bottom of the handle. I shape the brush the way I want it, and then I hollow out the hole. I used to use lathe tools to hollow the hole to custom specs, but now I use a sawtooth bit in a Jacobs chuck in the tailstock to make the hole more precisely, if not as uniquely.
The handle is then parted off, and I turn it around and load it in an expanding Collett Chuck and hold it in the 4 jawed chuck and finish the bottom nicely. I used to use a homemade jam chuck, but these Collett Chucks are my new toys.

Here is the 4 jawed chuck with a piece of Poculi just after the handle had been parted off:


Here is the Jacobs Chuck with a 1 1/8” bit. A 28mm knot fits this well. I also have a 1” bit for 24mm knots. Any other size, I still hollow it out with tools. As well, here is one of my expanding Collett Chucks and you can see how it would fit into the hole. There is a hex key on the end that allows you to tighten it:


So turners- what do you do?

Use a jawed chuck? Use a screw chuck? Other techniques?

How do you finish your bottoms? On the lathe or off?

Hold the handle with a jam chuck? Collett Chuck?

Any particular tools become favourites? Skews? Scrapers? Gouges?

Anyone drill the holes on a drill press after you have shaped the handle? Before?

Those of you who pour resins, any pics or techniques you’d share?

Anyone turn handles ‘back to back’ two at a time?

Any other materials besides wood or resin you have experimented with?

You don’t have to give up your trade secrets, but I think there are folks who will find what you do interesting!

I’ll write another post with shaving and lather bowls in a bit.

Lets see what you’ve got!!!

Really nice work, Jason.

Excellent idea Jason. Nice job on the pictures.

This will be fun to follow!

I’ll be watching too

Great idea for a thread, Jason! We have a lot of talented folks here, and I look forward to seeing all the beautiful work!

Jason, I really like your work. I have been inspired by many of your pieces.

So turners- what do you do?
The best I can. I still have all my fingers and both eyes.

Use a jawed chuck? Use a screw chuck? Other techniques?
Oh, I wish I had a jawed chuck sometimes. I just use a spur center and a live center for the tailstock.

How do you finish your bottoms? On the lathe or off?
I finish the bottoms off the lathe. I tend to try to dish them a bit so they sit nice and solid.

Hold the handle with a jam chuck? Collett Chuck?
Nope. Don't have any.

Any particular tools become favourites? Skews? Scrapers? Gouges?
I just use whatever works best at the time.

Anyone drill the holes on a drill press after you have shaped the handle? Before?
That's me. I drill a pilot hole and then follow up with a Forstner bit.

Those of you who pour resins, any pics or techniques you’d share?
No. I do not.

Anyone turn handles ‘back to back’ two at a time?
This I do from time to time. I even did four at a time once (see below).



Any other materials besides wood or resin you have experimented with?
I have only done two resin/wood hybrid brushes. You can see that I turned them together above. I also did some laminated wood.

You don’t have to give up your trade secrets, but I think there are folks who will find what you do interesting!


I’ll write another post with shaving and lather bowls in a bit.
I would like to do a bowl one day, but I think it would work out better if I had a jawed chuck.

Lets see what you’ve got!!!
That's all I got. If you have followed me on my blog, I have pretty much laid it all out for everyone to see.

Great thread! Very interesting!

Although a chuck is not a cheap investment, it makes life so much easier on a lathe. Barracuda chucks have a great reputation. I purchased a Nova G3 as it was a bit less expensive and like it so much that I intend to purchase another one in the future so I can use Cole Jaws without swapping jaws on a single chuck (I turn bowls usually, when life isn't so busy). I would avoid the economy chucks, that use two metal keys (if that is what you call them), as I have found that they can loosen while turning - makes for a bad day. Plus, the other two vendors I mentioned can be tightened with one hand, making it a lot easier to use.

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Awesome, Jim! Thanks for posting. Your handles have been an inspiration for many. I love your Celtic inspired laminates, they are tremendously skilled work.

In response to your point about making bowls- Yes a Chuck is handy to have, but you can more than get by with a faceplate. You have to glue a piece of waste stock on the blank and then cut it off afterwards and finish the bottom off the lathe.
@9nein9 posted a pic of a few brushes done ‘end to end’ like yours. I would imagine he is also drilling the holes off the lathe as well.
As far as buying chucks goes, the expanding Collett Chucks I showed earlier are very inexpensive (I think I paid $24 for two) and do a great job of holding the handle from the hole. Even drilling off the lathe, you could them remount and finish the bottoms as you wish.
Sounds like I need to check out your blog!

Great points about Chucks. Mine does have the two metal ‘keys’ (it is also 20 years old!) but doesn’t ever loosen. I got it at Lee Valley, but don’t remember the brand. I’ll look it up.

"Any sufficiently advanced technology is indistinguishable from Magic" - Arthur C.Clarke

https://jrshaving.blogspot.com/2018/07/celtic-knot-jayaruh-310.html
This is #310. The Celtic knots are fun to make. The link reveals my secret.

That is beautiful Jim. What a great time to watch you develop into a professional brush maker. .

That beauty sits in my friend's den. He was floored when he received it!

Beautiful work!

@Jayaruh is a Master Craftsman and a gentleman as well!

It's nice to learn that my last name has a meaning in the shaving industry!!!! . (Turner)

That's an awesome brush!

Reminds me of a song: Turner Round, Look at Me...