Hi, everyone! This is Version 2 of my nunchuck design. It is updated to provide a cleaner aesthetic at the connection points, as well as have a simpler construction method. All parts were sourced from a common, large, home repair materials store.
(2) 12" x 3/4" Poplar dowel
(1) 12" length of regular paracord
(2) 1/4" x 3/8" x 1/2" steel spacers
(2) 1/4" brass electrical crimps
Sandpaper for finishing: 60 grit, 180 grit, 400 grit
Drill bit size: 23/64" (this size is slightly smaller than the 3/8" diameter of the spacer, in order for the spacer to press-fit into the handle)
Step 1: Create the Connector
The rope that connects the two handles is simple black paracord.
1. As seen in the pictures, double-back the 12" paracord to provide dual 6" cords. Doing so will make one end a simple bend, while the other end will be split. On the split end, use fire to melt & seal the end of the paracord.
2. Slip in the steel spacers. For my personal preference, the spacers are approximately 4" apart as measured between the inside edges.
3. On both ends, clench the brass crimps using pliers, then bend them into a 'C' shape in order to fit within the holes that will be drilled within the handles.
Note: I set the length of the paracord based on my preference for the distance between the handles. This length can be adjusted based on your own preference.
Step 2: Prepping the Handles
1. Determine which ends of the handles will be drilled to accept the cord connector. On these ends, sand down the edges of the wood, using progressively higher grit sandpaper, to create a smooth rounded surface on which the cord can travel.
2. Using the 400 grit sandpaper, buff the whole handle to create a smooth surface. Note: this was the extent of finishing I performed on the poplar wood because I didn't want to handle lacquer. Feel free to finish to your preference.
3. Using the drill bit, center the bit within the rounded-edge end of a handle, and drill approximately 2" straight into the wood. Do this for both handles.
Step 3: Attaching the Pieces
1. Press-fit one end of the cord connector into one handle such that the steel spacer fits flush with the top of the wood. The fit should be really tight.
2. Perform the same press-fit on the other handle.
Afterward, enjoy your new chucks! So far, the press-fit connection has maintained its strength, and seems to handle my relatively-wild style of chucking.