I wanted to share with you the repair of a a crumbled barrel end of a gorgeous oversize Wahl Eversharp Doric in cathay color.
I cleaned the end barrel removing all the crumbled celluloid.
I decided to rebuild the Barrel end crown using another broken doric cap in cathay color (junior size) (also crumbled at the end): here is this cap (yellow arrow shows instable cracks, I got it on ebay for 30$):
I first removed all the "unhealthy celluloid" (broken or crumbled parts) from the broken doric cap. I then used sand paper to remove the discolored superficial layer of the cap. Here is what remained of the cap:
Then the barrel was split in half using a fine jeweler's saw and sawn the splited barrel in "tiles" of the width of the barrel end: here are the tiles:
Then the tiles were flattened and glued together using acetone welding. You must immerge a short time each tiles in acetone to allow them to soften. The tiles are then ready to be assembled two by two by pressing them against each other. On the left of the picture you can see tiles already assembled and on the right a fresh one ready to be soaked in acetone and welded to the other ones.
And now the hardest part!: you have to wait for 3 months to allow the dice to dry (to shrink).
It's now time to acetone weld the dice onto the end barrel:
Then the crown is sculpted, sanded it down to the 12 lateral facets of the doric barrel with rough sand paper. To guide you and to avoid damaging the lateral facets of the barrel you have to protect each facet with a piece of metal taped with double sided scotch tape onto the barrel facet:
Here is the rough result on the left (without fine sanding) and with fine sanding on the right (up to 5000 grit sandpaper):
When you have finished with sculpting the 12 lateral facets it's time to sculpt the crown (end side). You have to sand it using a metallic guide taped with regular tape on the lateral facets:
After finishing and sanding using Micromesh (grit 8000/12000) here is the result:
The pen after a year of use didn't show any signs of crumbling, there was no celluloid shrinkage either:
Edited by Hardy08, 21 January 2020 - 12:51.