Instructables

Hammer handle from a large threaded rod and PVC

For this Instructable you will be making a super strong hammer handle from a large section of threaded rod, and PVC. 
 
Materials
--hammer head
--a large bolt that is about 1 foot long
--2 nuts that fit onto the bolt, whatever size that may be
--gorilla glue
--scrap PVC
--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!

Picture of Glue!
DSCN0747.JPG
DSCN0748.JPG
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

Picture of Heat and clamp
DSCN0752.JPG
DSCN0751.JPG
DSCN0750.JPG
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!
 
Remove these adsRemove these ads by Signing Up
cart562 (author) 2 years ago
Pretty much right after I made the first one I made the large hammer handle here and just recently I made the handle for this hatchet that I was just waiting to break on me. I quite like both of them but the bolt I used for the hammer is really thick so it ended up being super heavy, not quite ideal for hammering nails but good for just smashing things.
DSCN1091.JPG
Phil B2 years ago
This is very clever. I would think the nut on the upper end of the hammer would make it a little less easy to use for pulling nails with the claw. The nice curved edge that facilitates rolling the hammer while pulling the nail is interrupted.
pfred2 Phil B2 years ago
I agree Phil that this probably isn't the best method to fix a claw hammer. Fitting a wooden handle properly might be tricky though if someone does not possess some skills, know a few tricks, whatever one wants to call it. I have a few tricks today that makes it come out good for me.

Lots of folks have written about putting handles on hammers though so I'm not going to bother doing that. I did put up an article on this site about making a hammer head.

That is something I've only done once myself so far. Once I got done with it I had to fit a handle to it though.

http://www.instructables.com/id/Brass-Hammer-Build/
blkhawk2 years ago
Great project! I have tried to replace handles the conventional way but they always end up broken after a few times. This is a great solution for a broken hammer handle.
l8nite2 years ago
neat save ! I would have used locktite or a double nut on the top to ensure it doesn't come loose, better yet would be a long bolt.. thank you for sharing
cart562 (author)  l8nite2 years ago
Can you get large bolts with threads so close to the top? If you can then yes that would be much better but what can I say? I use what I've got
l8nite cart5622 years ago
I wasn't faulting your idea, I'm well aware that using whats on hand sometimes limits you. My suggestion was more for someone else who may try this (like myself) Long bolts are available at a good builders supply if not at the big box home improvement stores. I don't think that if they were a little shorter than the handle it would make a big difference as long as there is enough to securly grab the epoxy
pfred22 years ago
I used a lower control arm bolt as a handle for one of my hammers. Then I glued a rubber handle I got off a cheap axe onto it. You can see it in this picture:

http://img826.imageshack.us/img826/5993/t5001.jpg

It is pretty indestructible now.