For this Instructable you will be making a super strong hammer handle from a large section of threaded rod, and PVC.
--a large bolt that is about 1 foot long
--2 nuts that fit onto the bolt, whatever size that may be
--heat gun--optional, I guess
--bench vice--if you use the heat gun
Step 1: Break a handle!
I guess this is the part when you either pull a little too hard, turn it the wrong way, or your hammer is just a bit too old. Since I'm me, however, I forgot you're not supposed to pull non-metal hammers straight back when pulling nails and I naturally applied way too much force and broke it. I break my tools a lot. After the 'Oh, crap!' moment; you need a new hammer handle.
Step 2: Remove the old handle.
Usually part of the handle is still stuck in the head so you can either drill it out, chisel it out, or just toss it in a fire and burn it out! The burning is definitely the easiest if you burn a lot but the drilling is really not trouble if you're worried the fire might harm the head somehow.
Now, the hammer I had, wasn't wood. It was some kind of fiberglass handle and it sure was some nasty stuff. I had to cover my face when I drilled through it because of the dust and I would advise the same if your handle isn't wood.
Step 3: Place and tighten the nuts
This step is very easy, just get some nuts that fit onto the rod that hopefully you already have in the big collection of nuts and bolts that everyone has.
Find two wrenches that fit or two adjustable wrenches or whatever.
Tighten! I like to apply a lot of force and I manage to get mine extremely tight and snug. Also, since the head slopes down towards fork end so when I am hammering, the bolt will be forced forward more so it can only get tighter, not looser.
Step 4: Prepare the PVC
The pipe I used was scrap from my first PVC bow which was 1/2 inch pipe with a ripped 1/4 inch pipe inside of it. If you have some scrap I would recommend using two sections like this or just a 1/4 inch and then apply something on it afterwards for a better handle.
Cut your pipe to whatever length you rod is with a hacksaw or coping saw; which is what I used.
The words will need sanding off so get a 60 grit or lower for the job.
Step 5: Glue!
Gorilla glue is my favorite and it's something I have so I went with that. First I dripped it down the pipe and coated the insides but I wanted to use a lot so I put some down the length of the rod. I spun the pipe a bunch and made sure that the glue got everywhere in and around there before setting it out to dry.
I left it standing upside down for one night and continued work the next day; even though the glue wasn't dry then.
Step 6: Heat and clamp
What I did next was I took my heat gun and heated a section of the handle until it was soft and then I clamped it as tight as I could in my vice, which is pretty dang tight. I love my bench vice; it is one of the tools I used the most in my workshop.
If you've never heated PVC before, it is fairly easy. You can use a small propane torch, gas oven, or even just a fire but my new heat gun definitely works the best and will not burn before it is softened. If you only have a torch then you must be careful not to burn the PVC. I don't know how well heating it over an oven works; for more info, http://www.instructables.com/member/Thinkenstein/
Once the PVC is softened, it will stay soft and malleable for a few minutes, depending on how hot you got it but it will need to be clamped for at least 2 minutes to cool.
Step 7: Sand, paint, etc.
I personally didn't really do much more than sand mine a bit. If you do actually make something like this, then feel free to paint it if you have paint but I have a lack of that so it is still plain and white. Thanks for reading my Instructable and happy crafting!