How To Make Tool Handles Without A Lathe

I first reduced the diameter of one end until the ferrule would just tap on tightly.

How to make tool handles without a lathe. First I use a razor blade to make a 1-2 inch vertical cut through the section where the belt is spliced together this is the diagonal line that goes across the sanding belt. Then turn the rest of the handle down to the correct measurement using a parting tool. The ferrule is made from part of a plumbing 90 degree fitting and should be a tight fit on the handle.

First replace the roundover bit with a straight or core-box bit. I used braided vinyl but you can. For making a lathe first you need to cut plywood parts of the same size.

The idea is that the tool will be inserted into a handle usually metal and purchased separately having set screws or a collet to hold it in place. Turn on the lathe and check to see that the handle runs true. Cut the blocks in the same size.

Next set the bit height and then clamp a stop to the fence to establish the tenon length. There should be little or no ghosting at the ferrule end. The ferrule could be a short piece of pipe super glued onto the round tenon.

If no welding is available you could drill through your newly made hole saw and turn it with a steel rod through the holes. If the tool needs to slide up into the handle drill a hole 164 inch larger than the tool and as long as needed. The best choice of the plywood sheet is 10-12mm and 17-21mm to make a lathe.

Making a Tool Handle. Without a design you can turn one handle but will never be able to get consistent-looking handles for a set of four. The ferrule should bite into the shoulder of the tenon for a nice snug fit.