Right, my Omega brush got smashed to bits the other night, so I've decided to make a new handle to fit the knot.
I've used a piece of English Oak, so it's similar to my current razor handle.
To start off, I've chucked up a block of Oak, cutting it slightly longer than I need
I then drill a hole big enough to accept the knot
Once I drill the hole, I'll mount between centres and turn round
Once rounded, I'll reverse it and shape the handle, then sand it (start at 180 and work to 600 grit)
Pop the knot in to double check it fits and looks good
Finally, it's time to seal the wood and varnish. I'll give it a quick wipe with some baby oil to raise the grain and remove any dust leftover from sanding. Then I'll use a couple of coats of sanding sealer. This toughens the wood fibres and makes the wood more accepting to a finish. I then put the first of 2 coats of marine varnish on. This will provide a waterproof, heatproof finish.
I'll update the thread once this process has finished with the next stages.