chunk of wood
3/8" aluminum tube
1/4" aluminum tube
1/8" brass rod
star lock washer
2 part epoxy
your choice of wood finish
drill/ drill press
3/8" drill bit
1/8" drill bit
Step 1: Materials
Step 2: Making Your Cuts
Now, measure how much room you need to make the star washer fit in the aluminum tube. Mine was around 1/8"
cut you wood to length
trim the 1/4" aluminum tube to fit in the 3/8" aluminum tube
Step 3: Drilling and Deburr
Take the file and straighten the cut up and remove any burrs on the 3/8" aluminum rod.
Step 4: Shaping the Wood and Aluminum Rod
Then, shape the wood, I shaped mine to comfortably fit my hand
Step 5: Completing the Lower Part
Allow time to dry, then cut the brass rod to length, insert the rod through the recently completed star washer assembly and 3/8" aluminum rod and peen brass rod. Check to make sure the brass is properly peened and uses a belt sander to remove any extra brass.
Then trim the 3/8" aluminum tube so that it will properly fit in your handle.
Check to ensure it fits in the handle.
Step 6: Finish the Wood
Step 7: Epoxy the Two Together
Allow time to dry
Step 8: The Completed Tool & Thoughts
This turned out great and I will likely make a few more.
However, the two main complaints I have about this tool.
1. The wood I used for the handle was still green and did not take to the stain well. (Still functions and looks good though)
2. The spacing on the star wheel is a little tight; I might trim every other prong.
Overall I really love this new tool and i'm sure it will serve me well for many years!