Making a flat top brush

Discussion in 'The Brush' started by oscar11, Feb 3, 2018.

  1. oscar11

    oscar11 Well-Known Member

    Some people have asked to see the process of making this flat top brush. This isn't the only way or the right way to make a brush it's just how I do it. This is a Shavemac DO-1 silver tip knot, 25mm x 53mm.
    I've worked with DO-1's before both 2 band and silver tip so I had a preconceived idea of what I wanted for loft. Because of it being silver tip and a flat top I knew I would shoot for a loft of sub 50mm ( below a 2 to 1 ratio) and I'd mount slightly lower than a fan of the same material.
    1) the materials rough cut to length.
    2) Finding the centers. Not really needed but if I end up taking the piece out of the lathe it makes life easier.
    3) Handle base mounted in the lathe. I cut a tenon on the base and drill a matching hole in the top of the handle.

    4) Gluing up the pieces and letting it cure.
    5) I'll part it off to length (white part) and drill the hole to depth.
    6) Drilled to depth and rough shaped.
    7) Tuning the depth of the knot.
    8) Depth corrected, finish sanding and parting off the handle. Finish sanding is done by hand off the lathe. Buffing is done with a cotton wheel. The knot isn't glued to allow for final adjustments if needed. In this picture the knot has been used once (still not glued) and as you can see slightly crooked. No biggie, I'll shave with it a few more times before final gluing.
    It's lofted to 44mm and very close to where I want it. The brush is huge because of the flat top but I was very pleased with it performance. I'll give it a few shaves before I decide to glue it.
    Last edited: Feb 3, 2018
    AlDm, lloydrm, TitanTTB and 17 others like this.
  2. TestDepth

    TestDepth Well-Known Member

    Great description & pictures. Thank you for giving us insight into how you make those beautiful brushes!!!
    RyX and Zykris like this.
  3. PatrickA51

    PatrickA51 Well-Known Member

    Excellent. Great post and very interesting. I see another work of art in the making.
    Semper Fi
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  4. jimjo1031

    jimjo1031 never bloomed myself

    nice job...........
    PatrickA51, TestDepth and Zykris like this.
  5. Keithmax

    Keithmax Breeds Pet Rocks

  6. richgem

    richgem suffering from chronic clicker hand cramps

    That's purdy!
    PatrickA51, TestDepth and Zykris like this.
  7. MoAllen

    MoAllen King of Unscented

    Thanks for sharing photos of your work. I love to see how people build things.

    Sent from my RS988 using Tapatalk
    TestDepth and PatrickA51 like this.
  8. Jayaruh

    Jayaruh The Cackalacky House Pet

    Supporting Vendor
    Beautiful work, Steve. I love what you do.
    TestDepth and PatrickA51 like this.
  9. Marine68

    Marine68 Well-Known Member

    Great work Marine, Semper Fi.
  10. canoeroller

    canoeroller Well-Known Member

    Very nice. Love the proportions on the handle.
    Marine68 likes this.
  11. Marine68

    Marine68 Well-Known Member

    @oscar11 Can a brother Marine get you to make him one like this?

    Semper Fi
  12. Sara-s

    Sara-s This Pun for Hire

    That's another stunner. What glue do you use to glue to fasten the 2 parts of the handle together?
  13. Douglas Carey

    Douglas Carey Wildman

    Good job. Thanks for posting. :happy088:
  14. RaZorBurn123

    RaZorBurn123 waiting hardily...............

  15. Enrico

    Enrico Popcorn

    WOW :happy096: :signs107:. You do great work and :signs154:
    Douglas Carey likes this.
  16. Shadow Shaver

    Shadow Shaver Well-Known Member

    Nice looking brush. I love the blue, great job.
    Douglas Carey likes this.
  17. wchnu

    wchnu Duck Season!

    Great work!! Did anyone see this and decide they had to have a flat top brush now??
    Enrico and TestDepth like this.

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