Tool Modification (Pits and Porosity)

Hey everyone, haven’t had a bunch of time lately to write new content, but here is a blast from the past…..

Tool Modification (Pits and Porosity)

Ready for another quick lesson? Today I get to address one of my favorite-est (not a word) subjects in the world….. Tool Modification. I mentioned before that I seldom throw away tools, bits, burs, etc. I am always trying to find a way to modify them into new uses. For one reason, I can make tools for the exact job I am doing, and 2, it is a free way of expanding my tool arsenal. (you should see my garage…..)

Here is a quick way to make a tool that works wonders cleaning those hard to get into areas. If you have a small used up bur, snap/break off the end and grind of sand with a sanding disc with between 3 and 6 different angles or “facets”.

Bit4 Bit3

These edges when spun in a Foredom work as a powerful burnisher that will grind and smooth rough areas that ordinary tools and burs can’t reach.


If you work with casted pieces, then you are no stranger to pits and porosity. This little tool also takes care of small pits and porosity, where trying to polish these away usually just reveals more pits and porosity. Use this little rotary burnisher to rough up and “smear” the metal over the bad areas, then when you sand and polish, unless the porosity is extreme, you should be able to remove or repair these areas.

Porosity1 Porosity2

Burnished2 Burnished1

I have a huge selection of burs, burnishers, grinders, texture-makers, and pit-beaters to select from that I have made over the years.

Tools Reused

Now, put on that creative cap and make some fun tools to experiment and play with.


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6 Responses to Tool Modification (Pits and Porosity)

  1. Jen August 15, 2015 at 2:24 pm #


  2. Johnna August 17, 2015 at 8:44 am #

    Good to see you – I’m so glad that you’re back, and I am looking forward to see more of your usefull tips and tricks. They’re so inspiring …

    • JewelryMonk August 17, 2015 at 10:24 am #

      Thank you Johnna!

  3. Susan August 17, 2015 at 10:01 am #

    Thanks for this post. I shared it on aspiring metalsmiths as I thought it was a very good and thrifty tip! I love tool modifications! Don’t hesitate to share any “blasts from the past” because it keeps those of us who are a tad lazy (who me?) from having to dig through old posts to find gems such as this! Susan

    • JewelryMonk August 17, 2015 at 10:23 am #

      Thank you Susan!