---
title: Make a climbing brush
slug: make-a-climbing-brush
description: Create a climbing brush using plastic and woodworking techniques to achieve a unique pattern.

An oven is required; powered tools like a sander, saw, and router are recommended for ease.

For feedback or suggestions, please leave comments or contact us on social media.
tags: ["melting","HDPE","product"]
category: Products
difficulty: Medium
time: < 1 week
location: Hong Kong, Hong Kong
---
import { Image } from 'astro:assets'
# Make a climbing brush
<Image src={import('./DSCF5284.jpg')} alt="Make a climbing brush" />
Create a climbing brush using plastic and woodworking techniques to achieve a unique pattern.

An oven is required; powered tools like a sander, saw, and router are recommended for ease.

For feedback or suggestions, please leave comments or contact us on social media.

User Location: Hong Kong, Hong Kong
## Steps
### Step 1: Preparation

## Required Tools

- Oven
- Oven tray
- Two sheets of Teflon paper
- Oven gloves
- Mould: at least 12 in (30 cm) wide x 98 in (250 cm) long x 8 in (20 cm) high
- HDPE plastic
- White glue
- Saw (such as jaw saw or band saw)
- Sander (grit sizes: 40, 80, 120, 240, 400, 800, 1000)
- Polisher with wool pad
- Soldering iron
- Woodworking CNC router


<Image src={import('./DSCF4806.JPG')} alt="DSCF4806.JPG" />

### Step 2: Preparing Plastic (HDPE) Pieces

For this project, use HDPE as it is easier to work with than PP. Ensure the plastic is clean and labels are fully removed. Cut the plastic into pieces and sort them by color.

The quantity of plastic depends on the mold size. For every 0.06 cubic inches (1 cm³) of volume, one gram of plastic is required. In this example, approximately 1.87 lbs (850 g) of HDPE is needed.


<Image src={import('./DSCF4804.JPG')} alt="DSCF4804.JPG" />


<Image src={import('./DSCF4812.JPG')} alt="DSCF4812.JPG" />


<Image src={import('./DSCF4815.JPG')} alt="DSCF4815.JPG" />

### Step 3: Melting the Plastic 

Place the plastic sheet on the oven tray with a Teflon sheet between layers. If the sheets do not stack well, transfer them to another container with a Teflon sheet.

Preheat the oven to 180-190°C (356-374°F) and heat the plastic for 25-30 minutes until fully melted.


<Image src={import('./DSCF4818.JPG')} alt="DSCF4818.JPG" />


<Image src={import('./DSCF4821.JPG')} alt="DSCF4821.JPG" />

### Step 4: Stack, Cut and Knead

Remove the plastic while wearing thick gloves. Stack and cut the plastic, folding it as needed. Experiment to develop your method for layering different colors.


<Image src={import('./DSCF4832.JPG')} alt="DSCF4832.JPG" />


<Image src={import('./DSCF4838.JPG')} alt="DSCF4838.JPG" />


<Image src={import('./DSCF4841.JPG')} alt="DSCF4841.JPG" />

### Step 5: Melt and Repeat

After allowing a few minutes to cool, the "dough" will become too firm to knead. Return it to the oven, melt, and repeat until the desired pattern is achieved.


<Image src={import('./DSCF4860.JPG')} alt="DSCF4860.JPG" />


<Image src={import('./DSCF4861.JPG')} alt="DSCF4861.JPG" />


<Image src={import('./DSCF4839.JPG')} alt="DSCF4839.JPG" />

### Step 6: Forming Shape

When satisfied with the mixture, place it into the mold and press with a heavy object. Allow it to cool.


<Image src={import('./DSCF4842.JPG')} alt="DSCF4842.JPG" />


<Image src={import('./DSCF4850.JPG')} alt="DSCF4850.JPG" />


<Image src={import('./DSCF4851.JPG')} alt="DSCF4851.JPG" />

### Step 7: Cut the Block

If you have a larger mold, cut a strip approximately 1.18 in x 9.84 in x 0.98 in (30 mm x 250 mm x 25 mm) using a saw with a wood-cutting blade.


<Image src={import('./DSCF4869.JPG')} alt="DSCF4869.JPG" />


<Image src={import('./DSCF4873.JPG')} alt="DSCF4873.JPG" />

### Step 8: Glue the Outline and cut it out

Print the outline of the brush to scale and attach it to the strip using white glue. If the surface is uneven, sand it smooth. Cut the outline with an offset of 2-3 mm (0.08-0.12 in) for additional sanding.


<Image src={import('./DSCF4911.JPG')} alt="DSCF4911.JPG" />


<Image src={import('./DSCF4912.JPG')} alt="DSCF4912.JPG" />


<Image src={import('./DSCF4917.JPG')} alt="DSCF4917.JPG" />

### Step 9: Sanding into Desired Shape

Sand the plastic to the desired shape using sandpaper with grits of 40, 80, and 120. Either a belt sander or a hand sander can be used effectively.


<Image src={import('./DSCF4919.JPG')} alt="DSCF4919.JPG" />


<Image src={import('./DSCF4921.JPG')} alt="DSCF4921.JPG" />

### Step 10: Fill Holes

To address any gaps in the brush, use a soldering iron to fill them with leftover materials. Trim excess plastic with a cutter and sand the surface.


<Image src={import('./DSCF4927.JPG')} alt="DSCF4927.JPG" />


<Image src={import('./DSCF4930.JPG')} alt="DSCF4930.JPG" />


<Image src={import('./DSCF4943.JPG')} alt="DSCF4943.JPG" />

### Step 11: Fine Sanding and Polishing

When the brush shape is formed, sand up to 1000 grit (18.5 microns). Then polish with a wool pad at high speed. If scratches appear, sand again. Wax can be used during polishing, but it is not essential.


<Image src={import('./DSCF4947.JPG')} alt="DSCF4947.JPG" />


<Image src={import('./DSCF4951.JPG')} alt="DSCF4951.JPG" />

### Step 12: Mill the Brush Head and Drill the Hole

Apply adhesive to the area to be milled on the brush, and then mill it with a CNC Router, keeping 1-2 mm (0.04-0.08 in) of the brush edge intact. Ensure the hole is at least 10-15 mm (0.39-0.59 in) deep to maintain the brush's firmness. 

Alternatively, drilling holes is possible, but this significantly increases the time required for hair insertion.

Drill an M3-M5 (0.12-0.20 in) hole at the end of the brush to attach a rope.

REMINDER: Use masking tape to protect the brushes.


<Image src={import('./DSCF4978.JPG')} alt="DSCF4978.JPG" />


<Image src={import('./DSCF4982.JPG')} alt="DSCF4982.JPG" />


<Image src={import('./DSCF4986.JPG')} alt="DSCF4986.JPG" />

### Step 13: Insert the Hair

To insert the hair, use 1/8 to 3/16 inches (3-5 mm) of epoxy. Fill the area with hair until it is full. Allow the epoxy to set.


<Image src={import('./DSCF4990.JPG')} alt="DSCF4990.JPG" />


<Image src={import('./DSCF4992.JPG')} alt="DSCF4992.JPG" />


<Image src={import('./DSCF4999.JPG')} alt="DSCF4999.JPG" />

### Step 14: Cut the Hair

To ensure the brush tip remains effective, maintain approximately 20 mm (0.79 inches) for the tip and 15 mm (0.59 inches) on the opposite end.


<Image src={import('./DSCF5002.JPG')} alt="DSCF5002.JPG" />


<Image src={import('./DSCF5006.JPG')} alt="DSCF5006.JPG" />

### Step 15: Go Climbing

Create a climbing brush and use it at your gym or crag to clean holds effectively.


<Image src={import('./DSCF5284.jpg')} alt="DSCF5284.jpg" />