Step 1: Find a Saw Blade or Tool Missing a Handle
Step 2: Shape Basic Handle Shape
Step 3: Cut Slot for Blade and Hole for Screw
Once the basic form was set, I took the handle out to my band say and cut a slot for the blade.
Since this type of plastic becomes moldable at higher temperatures, I made sure to go slow here so it didn’t become too soft as I was cutting the slot for the blade. I then went to the drill press to drill a screw hole to attach the blade to my new handle. The same concern here for being careful when drilling the hole. I didn’t have problems with either situation, but wanted to point them out as it is a unique property of the material.
Step 4: Attach Blade and Add Final Shape to Handle
In the first step I was mostly concerned with the overall handle shape. To make sure the handle was comfortable to use, I re-heated the handle one more time in some hot water just until the outside became soft and slightly squeezed it. This left a custom imprint in the material which fits the contours of my hand exactly. This allows me to get a really great grip on the handle without a lot of strain on my hand.
So, for the cost of a couple of dollars worth of InstaMorph, I have a saw handle the is a perfect fit to my hand, and allows me to trim all those low branches. Problem solved!
If you want to buy some InstaMorph and try this yourself on a tool lying around the house, order it off their website at http://www.InstaMorph.com or just search “instamorph” on Amazon.