Part One of my investigation into Japanese Burnishers concluded by mentioning the next step would be to make a larger version with a Delrin sole.
After testing this new iteration for a couple of weeks, I find the larger size much more useful for the way I work, perfect for high pressure/ low friction applications. Paper conservators may find the smaller, more precise tool desirable. Both sizes have a plum wood handle which is attractive and has a silky smooth feel. They are easy to make in five steps.
The basic premise is simple: all you have to do is remove everything that is not the final shape of your burnisher.
- Rough out the wood with a bandsaw, a turning saw, or coping saw using the template below, or one of your own choosing. Fruitwood is ideal for this, at least 5/4 thick.
- Refine the basic shape using a carving axe.
- Smooth the axe work with a spokeshave and define the inner curve with a half-round rasp.
- Sand everything smooth and add a Delrin (or material of your choice) sole. Screw into place. Tips on shaping Delrin.
- Finally, apply a coat of your favorite wood finish. I like Watco Danish oil finish for this purpose, which in this case darkens the plum wood beautifully.
I keep finding more uses for this tool, most recently while laminating museum board to make wooden board thickness boards for a rebinding. It is also great for smoothing linings on the inner trays of drop spine boxes, or other operations where a lot of pressure is necessary. The heel of the sold is rounded in order to apply extreme pressure. The raised handle makes it easy to pick up, and it looks quite attractive sitting on my work surface. Even a client has commented on it.