24 July 2008

How to varnish a whole rod blank


Tools needed:
  • fine sandpaper
  • methylated spirit
  • cloth
  • sharp knife
  • plastic bottle
  • thin rubber sheet
  • needle
  • meths burner
  • cigarette lighter
  • gloves
  • varnish/epoxy
  • measuring cup
  • bench vice
  • old newspapers
  • pliers

STEP 1    
Butt Assembly Butt Assembly

a)

Clean the blank by rubbing down with fine sandpaper.

  

b)

Using methylated spirit and cloth, clean the blank.

 


STEP 2    
Butt Assembly Butt Assembly

a)

Make a varnishing spreader.

  

b)

Cut neck from bottle.
   
Butt Assembly  

c)

Cut hole in screw cap.

  

d)

Cut thin rubber sheet to fit inside lip of plastic cap.
   
 

e)

Heat up needle in flame.

  

f)

Burn hole in rubber sheet.
   
   

g)

Assemble bottle neck, rubber disk and cap.

    

 


STEP 3    
Butt Assembly Butt Assembly

a)

Place vice on to old newspaper and clamp rod blank in vice. Be careful .

  

b)

Push the bottle cap down the rod blank to the bottom.

 


STEP 4    
Butt Assembly Butt Assembly

a)

Mix the epoxy coating or varnish in accordance with the manufacturer's instructions.

  

b)

Add mixed varnish or epoxy to the bottle cap.
   
Butt Assembly  

c)

In one motion gently pull the cap containing the varnish up off the blank. This will give a thin, even coating all around the rod blank.

  

d)

Hang blank up to dry in a door frame with newspaper underneath to catch any drips.

 

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