Materials and Tools Required:
-1/8 inch plywood cut to a dimension of 4 inches by 24 inches
-4" x 4" lumber cut to 12 inches (you can use anything from pine to maple)
-1/4 inch thick rubber sheet
Step 1: Turning the Handles
The handles for this board were turned on the TechShop Menlo Park wood lathe in less than two hours. Find the centers on either end of the 4" x 4" lumber (pine in this case) and mount it on the lathe using a spur drive center and cup center. Set the spindle to between 600 to 800 r.p.m. Turn the piece down to a cylinder using a 1" roughing gouge. Begin forming the handles with a 3/8" spindle gouge. The diameter and design of the handles are based on personal preference; they should fit comfortably in your hands.
Using a compass, a pair of dividers, and a contour gauge, constantly check to ensure both handles are the same size. Don't worry about making them absolutely exact to one another; handles need to be functional, not perfect.
Once the roughing is finished, it's time to move on to the sanding.
Step 2: Sanding the Handles
After finishing with the 220 grit, part off the handles using a parting tool and crosscut saw. Once the handles are removed from the main stock, sand the tops and bottoms smooth using a belt sander.
Step 3: Assembling the Board
Using a drill press, drill pilot holes into the center of the handles. Be sure to starting drilling the hole in the bottom of the handle, and do not drill all the way through. This is to keep the handle from splitting when attaching it to the board.
Place the handles over the holes, and drive a screw through until they are tight against the plywood. The screws need to be long enough that they firmly hold the handle, but short enough that they won't pierce through the top. Two inch screws are typically a good option.
Step 4: Attaching the Rubber
Cut the rubber with a razor blade; make sure it is slightly larger than the size of your plywood. Apply spray adhesive to the plywood and firmly press the rubber onto the wood. Let the adhesive set up for a few minutes. Clamp the board into a vice and use the razor blade to trim the edges of the rubber flush with the plywood.
The final step is to add the sandpaper. For this there are a few options. You can buy rolls of sandpaper that are the width of your board. Simply cut strips and apply with spray adhesive (you can also buy rolls that have adhesive backing already). Another option is to simply buy sanding belts for belt sanders, cut them to length, and apply with spray adhesive.