[necrobump]
I made this from a kit a few years ago, just after I started smoking a pipe...
The kits are a good way to get started because the drilling is all done for you - you basically just have to carve the outside and finish it. This was done freehand, mostly with a Dremel type tool and files after rough shaping with a junior hacksaw. I tried using a knife at first and immediately gave up - briar is incredibly hard.
A few months ago, I ordered some briar blocks and moulded unfinished stems, and made this...
The block and stem behind are the same as what I started with. The bowl was drilled using one of those woodworking spade bits with the pointy bits ground off, and the draught hole with a long 4mm drill bit. Most of it was done on a small metalworking lathe with a 4-jaw chuck (grips the block nicely), with some of the shaping done on an electric sander (cant turn the outside on the lathe when you get down to where the shank is). Mostly small files and sandpaper for the final shaping. The tenon was turned down in the lathe to get a good fit, and the shaping around the shank and stem was also done by turning to get the surfaces flush, with hand sanding to get the moulding flash off. Then all tidied up on a buffing wheel.
I think the staining was black leather dye (Fiebings oil based), then mostly sanded off (leaving dark flecks), followed by brown ink, and then a final going-over with carnauba wax on the buffer.
Both pipes smoke great - nice easy draw. If anything the big poker is probably too deep for me - I seem to have had my smoke and then find there's still 1/4 of the bowl left. It's also a bit narrow (18mm spade bit). For the next one, I'll try reshaping a wider spade bit (20 or 22mm) and go for a shallower bowl. I might get some shorter stems as well - these are a bit long and I can
just get a pipe cleaner in as far as the bowl to clear moisture. Can always do a shorter shank until then, though.
If anyone's interested, both the kit and the blocks and stems came from Alexander Zavvos on eBay (Mr Zavvos is no longer with us, but it seems that his family are carrying on the business, based in Greece.) Prices were very good - less than a tenner for a block and stem (bought in fives).