This video is by Jodee from Inspire Woodcraft. It’s part three of a four-part series that explores a modern take on Shou Sugi Ban—the traditional Japanese method of charring wood for preservation and beauty.
Jodee’s process combines burning, brushing, and coloring to create richly textured wood surfaces. In this part of the series, he breaks down the types of brushes used to shape the final look, from simple scrub brushes to advanced rotary tools.
Watch the full video and subscribe to Jodee’s channel:
Why Brushing Matters in Shou Sugi Ban
After the wood is burned, brushing removes loose char and reveals the natural grain beneath. The type of brush used has a major impact on the final texture, the color contrast, and how well additional treatments like stains or oils adhere to the surface.
Different brushes leave different tooling marks—some subtle, some bold—so experimenting with various types can help achieve a wide range of looks. Jodee has tested dozens of options and shares what works best for different goals and project sizes.
Starting Simple: Nylon Scrub Brushes
In the early stages of testing, Jodee used a basic nylon scrub brush—similar to what you’d find in household cleaning supplies. It does a decent job of removing soot without damaging the wood.
This brush leaves behind a smooth, subtle finish with minimal texture. It’s great for a clean look, but doesn’t expose much of the grain, making it harder for color treatments to stand out.
Stepping Up to Wire Brushes
Jodee then tried stainless steel and brass wire brushes. These are more aggressive and reveal more contrast by scraping away deeper layers of charred material.
Stainless steel brushes are stiffer and faster at cleaning, but can sometimes scratch too deeply. Brass brushes are softer and leave more visible tooling marks—fine scratches that add visual character.
Both options require more effort and can shed tiny wire fragments. Wearing protective clothing, gloves, and eye protection is recommended, especially when brushing large surfaces.
Power Options: Nylon Cut Brushes and Flap Wheels
To save time and energy, Jodee switched to rotary brushes like nylon cut brushes and nylon flap wheels. These attach to a drill or rotary tool and make fast work of the brushing process.
The nylon cut brush spins against the grain, which can leave circular patterns and requires careful control. It’s fast, but easy to overdo if you’re not careful.
Nylon flap wheels, on the other hand, spin with the grain. These come in grit levels like sandpaper (e.g., 80, 120, 240) and offer a more even finish without circular marks. Jodee recommends flap wheels for their control and consistency.
Choosing the Right Grit
Each grit level produces different effects:
80 grit removes material aggressively and reveals lighter wood tones beneath the char.
120 grit offers a balanced look—good grain exposure without being too rough.
240 grit provides subtle texturing and a smoother feel with less color contrast.
Testing on scrap wood helps find the right combination for your desired finish.
Larger Projects: Using the Porter-Cable Restorer
For brushing large volumes of wood, Jodee uses the Porter-Cable Restorer. This handheld rotary tool comes with interchangeable wheels and has a dust port for cleanup.
Wire wheels on the Restorer strip char quickly and add bold tooling marks. Nylon wheels help refine the surface after wire brushing, smoothing rough spots and preparing the wood for staining or sealing.
Other brands like Makita offer similar tools, though price and performance vary. Jodee points out that no matter the brand, safety gear is essential—these tools can shed wires and generate dust.
Comparing Wire vs. Nylon Wheels
Jodee typically uses both wheel types on large projects:
Wire wheels remove char quickly and create heavy texture.
Nylon wheels refine and smooth the surface after wire brushing, preventing snags and improving finish quality.
This two-step process gives the best of both worlds—bold texture with a refined surface.
Alternative for Large Surfaces: Nylon Push Brooms
When working on fixed outdoor surfaces like siding or fencing, a nylon push broom can cover more area in less time. It’s less precise but much easier on the back when brushing over large panels.
However, for detailed work or small pieces, rotary tools or hand brushes still offer the best control.
Summary of Brush Options
Here’s a quick overview of how different brushes perform:
- Nylon scrub brush: Gentle, good for loose soot, minimal tooling marks.
- Stainless steel wire brush: Fast and firm, reveals more grain, fewer scratches than brass.
- Brass wire brush: Softer, adds fine tooling marks and more texture.
- Nylon cut brush: Spins against the grain, fast but can leave circular scratches.
- Nylon flap wheel: Spins with the grain, comes in grits, great balance of speed and finish quality.
- Restorer (wire/nylon wheels): Powerful, best for large projects, must be used with safety precautions.
- Nylon push broom: Best for large outdoor surfaces with minimal detail.
Additional Tips from Jodee
- Holding brushes at a slight angle helps reach deeper grooves.
- Running a nylon brush after wire brushing helps reduce burrs.
- A drill press with a brush attachment gives even brushing pressure.
- Always test brushes on scrap before committing to your project.
Conclusion
Brushing is the key to unlocking the full visual impact of a Shou Sugi Ban-style finish. Jodee’s experience shows how different brushes—manual and powered—can dramatically change the texture, tone, and depth of your final piece.
For those starting out, a nylon flap wheel provides a solid introduction to rotary brushing. For more advanced or large-scale work, tools like the Restorer can save time and effort when used safely.
The right brush not only shapes how your wood looks but also how it accepts color and holds up over time. With the right combination, you can achieve bold contrasts, subtle grain definition, or anything in between.
Support Jodee by visiting his online store here: https://inspirewoodcraft.com/collections/all.