Step 1: Materials and Tools
A machete (from Harbor Freight)
Wood for Handle (broken shovel handle [other handles were not wide enough])
Some spare metal (1" wide strip I found in my barn)
Nuts Bolts, Washers (taken from the multitude)
Rasp (a large file)
Various other standard shop/workbench-type things.
Step 2: Disassemble Your Machete
Anyway, unscrew the screws.
Then, pry the handle apart. It doesn't want to go, as there are little pegs holding it together besides the screws. Show determination.
Step 3: The Metal Insert
Decide how long you want it. I decided on about that long.
Cut the piece. Depending on the type/thickness of metal and how large your machete is, you may want two. Turns out I didn't.
Place the machete on top of the metal insert where you will want it to end up. You want it to end up about as far up the machete as the previous handle was, and extending off the handle end with the rest. You may think of this as a handle extender if you prefer.
Take a screw or something that is lying around. Hold it, point touching the metal insert, inside the holes in the machete handle.
Give it a pound with a hammer.
Repeat for the other holes in the machete, where bolts will go.
These spots mark where to drill.
If I had done it this way, I would have been saved a bit of trouble.
Also, drill a hole down away from the existing machete, to make sure everything will hold together later.
Step 4: Make the Wooden Handle
take a shovel handle, put it in the vice, cut one end off, and rip it. Sawing down the length of something, as opposed to cutting across, is called ripping. I do not know why.
I made one initial cut, then made more cuts alongside it, just to take more material out. The shovel handle would have been too big around, especially sandwiching the metal.
Now, cut these off the same length as the metal insert/extender.
Drill holes through one of these pieces where the holes in the metal are. Then flip the metal piece over, and drill holes in the other piece of wood.
Step 5: Assembly
Pretty much, hold it all together and slip the bolts through. I had three main bolts, which passed through the machete, and one little bolt which held it together on the other end.
I slipped the bolts through, made a mark on them with the hacksaw where the nuts would about go to, and then removed them and cut off the extra with the hacksaw. This is so that there are not bolts sticking out everywhere. They only stick out as far as the nuts.
Put them back through, put the nuts on them, and tighten. I could have countersunk to let the nuts sit deeper (as well as the heads), but I would have had to walk to the house for the big drill (the little one couldn't hold a big enough bit), so I didn't.
Anyway, not the machete can be swing with two hands. Also, it looks like it's been through a lot more.