I had some scrap wood from some laminated pine board that I used to make a desk top on the cheap (steel angle, flat, and square tube, bolts, and pine board, with twine for support), thought I'd like to make a brush handle and it looked like a good candidate (turned out pretty well for the desk, anyway ;).
It's not done yet, but here's what I have so far:
Took some strips and cut them into about 1.25" square by 0.5" tall blocks, cleaned 'em with a damp cloth, put a thin layer of epoxy on the top of two of 'em, and clamped 'em all together (with some cheap 99 cent clamps). After it dried over night, sanded the edges so they were about flush, drew a circle on the top and bottom, then went at it with an old dull xacto knife knocking down the corners.
Not easy, but it's coming along. The worst part is trying to remove material from the end-grain sides, but I think I've more or less figured that out (hold block with side grain horizontal, end grain on left and right of block. Cut away from myself and toward the end grain using slicing motion, with blade at a ~45 degree angle respect to the grain) I'll have a Morakniv Classic 2/0 some time next week--should make things go a lot quicker--or smoother, at least. Might get a new blade for my xacto, too, for any detail work I need to do. Still not sure what the final shape will be...will probably evolve as I uncover the grain. I have a drill press to make the hole for the knot, but don't have a bit for that yet.
As far as color, not sure if I want to use the same stain I used for my desk top or go with a natural oil finish (flax is what I have on hand, but I may do another). I'll try a couple on some of the other scrap pieces and see what I like. Here's a couple pictures of the desk (before it got all cluttered up):
http://ift.tt/1KMoe63
http://ift.tt/1KMofH7
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My First DIY Pine Brush Handle
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