Bear with me on the tute. I might make this Malley Root one and take some pics as I go...
1. Basically though you get your block (plateau), plan the overall shape which will be largely dicatated by what you like and what your block will allow. Draw the side profile roughly on the block.
2. Plan the angle of the bowl and the outlet passage. Draw or scribe the centre line for these holes, and you will see where the outlet intersects the base of the bowl.
3. Also scribe the central plane around the outer perimeter block that the holes will need to line up (not the face that you drew the profile on - the top and side)
4. If you have a drill press with a vice excellent - if not you'll just have to be very careful with a hand drill.
5. The outlet passage first: Use a square to set your block with the passage line vertical in the vice - and precheck the depth you will need to intersect the bowl.
I use a 4.9mm drill bit (3/16) for the outlet passage. I drill that down to the intersection depth.
I then grab a 9.1mm bit and drill the hole for the brass pipe. The pipe I have is 9.5mm, so I will be tapering the ends of the pipe on the beltsander.
6. I then drill the bowl hole. I have a 3/4" ball-endmill which is great and gives a nice rounded bottom to the bowl, but a 3/4 drill bit will work fine, and just give you a more angular base - you could use a benchgrinder to round off the tip/flutes of the bit, which will render it useless on any other job but be good for pipe bowls. If you do this you may need to predrill a pilot as the very tip will be blunt.
Once you get your bowl hole close to the depth of the intersection check it regularly to make sure you dont go past your outlet hole. The outlet should be right at the bottom, slightly to the side.
7. Mouthpiece - Can be any wood as it isn't getting hot. As mentioned in the OP I add an extra step in the passage to cater for a filter option.
8. Once your holes are drilled you can just go for your life shaping her up with a beltsander. I use a 3" x 21" handheld jobbie which I mount belly up in a vice. Start with a 40 grit belt (wear kevlar gloves, eye protection, and a respirator please), then once you have her 90% to shape work through 120 grit to refine the shape, and 240 grit to smooth of the abrasive marks.
Shape the profile first, as marked on the face of the block, then get to rounding it all up , and thinning it down. You don't want it blocky, try to make it a bit elegant. Try to get the wall thickness around the bowl to 6-9mm (1/4" to 3/8"), with about 1/2" under the bowl. Consider grip and give it some curves to help it snuggle into your hand. I use the wheel far more than the plate.
9. Once she's all shaped up and smoothed off with 240grit belt, then handsand it with 240 grit, 400 > 600 > 800 > and 1200 if you can be bothered. 600 is fine and then cheat and use a calico buffer
. I oil them with "Organoil hard burnishing oil" which is a combination of Tung Nut oil and Citrus Seed oil. It dried a bit harder than Danish oil. DO NOT OIL THE BOWL OR THE PASSAGES - only the outside. Other finishes could be danish oil or Beeswax.
10. Cut your brass or Stainless pipe to length, bend it in a wood jawed vice, using some pipes to round off the curves you bend in to it. Trim it to just the right length. Then use your 240 grit belt (pref. one saved for metals, not your wood one) to bevel the tips down so they slide into your holes but tighten up nicely before they hit the end.
11. Running in:
Basically you need to give it a good layer of carbon before you want to run it at full temp. This will protect the wood from burning. Start with a 1/3 bowl for your first one and dont clean the ash out thoroughly. Then do a 2/3 bowl for your second one, again don't clean it out thoroughly. By then it's picked up the carbon layer you want and you can pack a full bowl and heat up the heart.
Alot of people will smear a virgin bowl with honey and flame it to caramelise it - which makes it taste 'nicer' , protects the wood from burning, and helps pick up carbon from the start. I don't think it's necessarily a good idea, and the Heath doesn't need to mask it's taste. It's very neutral.
Happy crafting folks, send photos
