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This guide will show you how to rewick a kevlar torch using kevlar thread. A properly wicked eating & fleshing torch has ZERO exposed metal (other than the main rod) as hot metal burns on contact. A properly wicked torch should also have a wick that is firmly attached with little wobble and no risk of coming off.

Disclaimer. Fire performance is a dangerous act and many precautions have to be taken to do it safely. Do not trust your own instincts or attempt to learn it on your own. Please reach out to a well trained professional in order to learn how to safely perform with fire. This is especially important for fire eating and breathing as improper technique may land you in the hospital or worse.

Supplies

An unwicked torch with a place to anchor at one end
Kevlar or other para-aramid thread
Kevlar wick (1-inch, 1.5-inch, or 2-inch)
A large curved needle. Leather or spade-tipped needles also work.
16ga steel wire (about a 2 inch piece, not galvanized)
Strong scissors
A pen or pencil
Painter's tape
(Optional) Pliers to pull the needle with
(Optional) A rubber band

Step 1: Preparation

Important Note. The pictures in this guide use flimsy decorative wire and red hemp thread to better illustrate the process. These are not the right materials and are only pictured here to provide contrast against the yellow kevlar. The red thread represents kevlar thread, and the blue wire represents 16ga steel wire

Prepare your materials in the following ways

If you are rewicking an old torch, remove all kevlar wick from the torch, as well as any screws or rivets holding it in place. If you can't get the old wick off the torch, cut most of it off and sew the new wick to the remaining stub, then skip forwards to Step 4.
Cut your kevlar wick to length and place painter's tape on the cut ends to keep it from unraveling. If you are rewicking an old torch, you can measure the old wick to find the length. Most torches use around 8" of material.
Thread a length of kevlar thread onto your needle and tie a knot to secure it. More thread is better, you'll want at least an 8" lead.

Step 2: Anchor the Wick Onto the Torch

Using a small piece of wire, anchor the kevlar wick onto the torch by folding one end of the kevlar over the rod and piercing it with the wire. The wire should go through both layers of kevlar as well as the anchor hole in the rod. Twist the wire to tighten it and fold it flat against the wick. Trim any excess. The kevlar wick should not come off at this point.

Tip: If you cut the steel wire at an angle, it will form a point that makes it easier to pierce kevlar.

If your torch originally used a screw to secure the wick, you can instead reuse the screw.

Step 3: Anchor the Thread

Push the needle through the kevlar but don't pull the thread all the way through. Separate the two strands of kevlar thread at the knot, then loop the needle around and thread it in through the strands. Pull tightly. This creates a cow hitch knot that anchors the thread and helps secure the wick in place.

Finally, push the needle through the kevlar once more, close to the edge of the wick. The thread should exit out the top edge of the wick.

Step 4: Roll the Sushi

Fold a few inches of kevlar wick in, then roll the kevlar wick up nice and tight like a sushi roll. At this point, you can use a rubber band to prevent the wick from unrolling.

After rolling, pierce the needle through all layers of kevlar, entering at the center of the roll (where it currently comes out), and exiting on the outside of the folded edge. Check the images on this step for reference.

Step 5: Start Sewing

Using a pen or pencil, draw a vertical line where the thread exits the wick, following the contour of the weave. Draw a second vertical line about a quarter inch from the edge, also following the contour of the weave. Finally, sew a few stitches between the two lines. The final stitch should exit out the bottom of the roll.

Step 6: Pull HARD!

Pull as hard as you can to close all of the bridging stitches. This will also pull the kevlar nice and tight. You can use a needle or a set of pliers to help pull the stitches evenly.

Step 7: Tie Off the Thread

With the thread sticking out the bottom, pierce the needle through the center of the bottom and exit close to the base of the thread. Use whatever method you prefer to tie off the thread. I like to loop a single strand of thread around the needle 2-3 times then pull the needle through and tighten.

Step 8: Hide the Knot and Cut

Push the needle back through the bottom of the wick next to the knot, and out the side of the sushi roll. Pull the thread TIGHT and cut it right at the base. The thread will get sucked into the wick and the knot will be hidden.