I didn't know where to start so I tossed it on the work bench where I would have to see it daily. After awhile I picked up the stem and cleaned it off. I managed to get the broken tenon out and I filled and polished the tooth marks. It looked pretty good!
Next I tried to get the tenon out of the shank. No joy! It remains in place to this day. But I had an idea. I had an old Dunhill inner tube on the bench. What if I used that to make a push tenon? I used some putty to hold it in place temporarily in the stem and I drilled a hole through the tenon in the shank the approximate size of the tube. It actually seemed to work. At this point I had to consider my next step so I laid it down again for a good while.
Six months or so ago I decided to fill the shank void with black epoxy. Maybe something else would be better, but that's what I had. It took awhile to get the fill right. And I had to keep reaming the hole. Lastly I filed it even and sanded and polished it smooth. The hole was a bit loose so I used a toothpick to slather a thin film of Super Glue in there. It worked! The tube now fits snuggly like a tenon should. I didn't get the stem alignment perfect. But I wonder if it ever was? It's close enough not to notice at first.
Last was the bowl. Alcohol did nothing to the thick crud. I used dental tools to clean the bowl and rim. Then I sanded the bore and used 220 on the exterior. I had to take the rim down a 16th or so. Then I used 600 grit and Micro Mesh polishing cloth. Lastly a couple coats of carnauba wax. The result isn't perfect, but the pipe looks pretty good and it should smoke fine. I have not epoxied the tube in place. It's soft aluminum. I'll replace it with a steel tube of the approximately the same diameter.
I'm pretty happy with the result. I don't smoke zulus. They hang down to far and tobacco falls out on me. But I had fun figuring out how to solve the problems.
Here's the pics:
