This project was built and designed by Jodee from Inspire Woodcraft.
Jodee shows how he made a batch of shou sugi ban–inspired charred-wood tap handles for a local brewery, covering material prep, installing threads, controlled burning, brushing, coloring, and finishing.
The video summarizes a workflow that balances repeatable jigs and batch techniques with finish-focused details that produce a durable, visually striking result.
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Design
The tap handles are simple, functional pieces meant to showcase the charred finish while providing a solid mounting point for brewery hardware. Jodee chose softwood stock to get deep texture from the shou sugi ban technique and left one face smooth for branding with a hot-stamp logo.
The aesthetic relies on contrast between the blackened grain and the lighter wood between grooves, so grain orientation and face selection were prioritized during layout.
This makes each handle read cleanly behind the tap while keeping the brewery’s logo area crisp and readable.
Lumber Prep
Pine/softwood stock was milled and sanded to create a smooth starting surface that would take the burn and dye consistently. Jodee emphasized picking the best face for appearance and marking each piece so the burn and dye would align with that reference.
To cut pieces repeatedly to the same length, he used a sacrificial table and fence for the miter saw with a stop block for consistent repeatable cuts. This kind of jiggery saves time and reduces tear-out when cutting construction-grade softwoods.
Threaded Inserts and Accurate Alignment
Rather than a visible screw or bolt, Jodee uses threaded inserts for a clean attachment to the tap stem and a sturdy, serviceable connection. He drills to accommodate the insert length and installs them carefully so the insert sits flush and true.
To keep the insert perfectly vertical, he threaded the insert in using the drill press installation bit while applying manual downward pressure and turning the piece by hand. Adding a little epoxy into the hole before installation helps lock the insert in place permanently.
Burning and Brushing (Shou Sugi Ban Technique)
Jodee uses a propane torch to char the wood in controlled up-and-down strokes, creating a zebra-like pattern where the softer springwood chars away more than the denser latewood. He then digs out the char from the grain to reveal contrast and texture.
For batch work, he made simple screw-on jigs so each handle could be burned and cooled in stages, allowing continuous workflow. Bringing the operation outside and using a clamp-on tray with a pipe clamp on his French cleat system made the process cleaner and faster.
Brushing Tools and Texture
After charring, aggressive brushing removes loose carbon and deepens the contrast between blackened grain and raw wood. Jodee uses stiff nylon/nylon-like brushes to scoop char from the grooves and get strong texture without over-smoothing the surface.
Brushing the ends and around the insert area is important because it cleans the grain and prepares the surface to accept dye or finish evenly. The result is tactile texture and more visual depth than a simple surface scorch.
Coloring and Masking for Branding
One face of each handle was left unburned and flattened for hot-stamping the brewery logo, while the remaining faces received dye. A water-based dye stain soaks into the exposed wood and tints the lighter areas without hiding the grain contrast from the charring.
Jodee sorted pieces by color tone first, applying red dye to boards that had a naturally redder hue to keep a consistent look across the batch. Careful sanding and dusting before stamping ensured the logo area remained flat and clean for a crisp brand impression.
Finishing
After coloring, the handles received multiple thin coats of satin polyurethane sprayed on for protection and durability. Jodee recommends three to four light coats for general use and mentions epoxy as an option if a very tough, spill-resistant surface is desired.
He also hinted at experimenting with this shou sugi ban process on a tabletop, where poured epoxy could fill the charred grooves and create a striking, stable surface. That adaptation shows how the same techniques can scale beyond small shop projects.
Lessons Learned and Adaptations
Jodee highlights small shop-made jigs and a staged workflow as essential for batch consistency and cleaner work. Simple fixtures like sacrificial fences, screw-on burning platforms, and a clamp-on tray can dramatically speed up repetition and reduce handling errors.
The methods used here are adaptable: the same approach to burning, brushing, and dyeing works for small accent pieces or scaled-up surfaces when paired with different topcoats.
Choosing the best face, controlling insert alignment, and planning for branding area are broadly useful decisions for functional decorative work.
Support Jodee by visiting his online store here: https://inspirewoodcraft.com/collections/all.