DIY Knot Setting - Proper sizing!

I'm hoping this helps at least a few people figure out how to properly shop for a handle & knot separately!

The most common issue I see is people coming to me with a custom handle that has an opening of exactly 26mm. While many think a 26mm knot is the logical choice, more often than not I'll recommend a 24mm knot for that size handle. Even though a 26mm knot is technically 25.5mm at the bottom of the glue base most times so that it can fit in a 26mm opening, often time you'll want a bit of buffer room so you can set the knot deeper in the handle easier. With the density knots are packed with nowadays, the chance of small glue bumps, it really makes the most sense to leave a bit of buffer room (1mm on each side can be nice, especially if you're setting knots 12mm+ deep).

Setting a 26mm knot in a 26mm handle opening usually limits you to only setting the glue base, at 10mm deep. From my experience, unless you're looking for a very easy splaying brush, this probably isn't an ideal setting height for most people. You'll notice a majority of european makers will set things around 52-54mm (or even less sometimes!).

For custom handles - it might make the most sense to send the knot to your artisan before hand if they'll allow it! That way they can ensure perfect fit.

For non-custom handles - always get your handle opening specs! then reach out to someone like me if you'd like help ensuring fitting, or simply give yourself a buffer of 1.5mm - 3.5mm for a safe fit.

tl;dr leave a bit of buffer room for deeper knot setting when buying a handle & knot separately!

Yep, I figure 1.5 to 2mm smaller than the "hole" as a rule of thumb, and I always set deeper than just the glue base. I like splay, but I like firm.

Great stuff Andrew. I talked about this a bit in my How to Glue A Shaving Brush Knot Into a Handle video. Digital Calipers come in handy.

Yep, I figure 1.5 to 2mm smaller than the "hole" as a rule of thumb, and I always set deeper than just the glue base. I like splay, but I like firm.

It is almost always the way to go! I’m with you there, it’s a fine balance between a good firm brush, with also suitable splay.

Great stuff Andrew. I talked about this a bit in my How to Glue A Shaving Brush Knot Into a Handle video. Digital Calipers come in handy.

Hey Garrett, do you have a recommended caliper, one that won't break the bank? I have set a bunch by eyeballing it, but since they are siloconed, I imagine changes some day. And setting new stuff, too! Thanks!

You might be able to find them cheaper at Harbor Freight, but these are the ones that I bought. Nothing special, but I did try to get a set that didn't have a plastic battery cover.

Digital Caliper - https://amzn.to/30JbgtJ

Or you can get a dial caliper, no battery to be dead at the wrong time. I use my old Lyman caliper from when I used to reload stuff, it's in inches but a few clicks on google converts to mm.

Wow, there are some cheap ones out there.

https://www.amazon.com/dp/B09SGK8SMW/ref...WNrPXRydWU=

AP Shave great post!  Bigger hole, smaller knot is definitely how things work.  Now calipers……there’s another rabbit hole!  In the case of measuring knot plugs vs handle holes a less expensive set of calipers works wonderful.  If however you have a whole bunch of machinists borrowing your calipers you’ll want to get higher precision (and better equipped machinists).  Those are anything but cheap.  As always, nobody is judging but I sure wanted to share with my fellow rabbits another hole to go down and festoon it with money!

For shaving brushes you really don't need any more than one of these.