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Hand-Cut Stem Making Process:

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Here I am making hand-cut stems for Fred's Cavicchi and David's Ferndown. Both will be cut from vulcanite rod. Here you see some of the tools I'm using. In the upper right is a 6" long, 9/64" drill bit along with a 6" long, 5/64" drill bit. Hole gauges and calipers help this process along.

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Here's the first stage in the drilling process. The Cavicchi is going to have an 8" churchwarden stem. 4" down I drill the 9/64" hole. Then the vulcanite rod is reversed and the 5/64" hole is drilled 4" down to meet in the center.

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Cutting the tenon.

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Now the stem blank is fitted to David's Ferndown. This is an extra stem. Don't worry, he still wants to keep the Cumberland.

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Here is the vulcanite stem on the taper jig.  This is run over a straight flute bit on my router table.  With a bit of shimming this taper will work on almost any length taper stem.

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The rod after the taper is machined.  The narrowest point is twenty thousands of an inch in width.  After shaping, filing and polishing it will end up a comfortable eighteen thousands.

Stay tuned, more of this process will be added in the coming days.