Introduction: Improved PVC Nunchucks
Are you interested in the world of martial arts? Or maybe you're only a juggling lover?
If the answer is YES, you've come to the right instructable.
First of all, I have to say that I've based this tutorial in these instructables:
I've changed a few things to improve them and the final result is a pair of professional, functional and well-built nunchucks. Continue reading and you'll find what I've modified in the next step.
Step 1: Modifications
I built a pair of nunchucks a few weeks ago with the indications of those instructables I've wrote in the main step. After using them a little, they broke as you can see in the video.
The reason was that the eyebolts were totally sticked to the pipe, and the PVC isn't too strong, so it didn't withstanded the effort.
The solution was easy: to improve the eyebolt hanging. The new ones are built to spin and move as you can see in the video, and they have a metal ring so the friction doesn't make the PVC suffer.
Step 2: Materials
First of all, all the materials you'll need are VERY cheap and easy to find. I've spent less than 7 euros (about 8$) in all the stuff (not including tools, but I suppose you'll have them at home or you can borrow them from a friend).
- 1 meter of PVC pipe, diameter = 3cm
- 4 end caps
- A tiny chain or a tiny strong rope
- PVC cement
- Two eyebolts with nuts (ATENTION: you'll have to ask for "secure nuts", as showed in the pictures)
-4 metal rings, with a hole a little bigger than the diameter of the eyebolts.
- Duct tape or electrical tape (optional)
-A CD marker (optional)
- A driller
- A pair of pliers
- Tongs (for cutting the chain)
- A saw
Step 3: Cuttig, Drilling and Sanding
The end caps I've bought had a border at the end, and I had to cut it first as you can see in the first two pictures. If you buy endcaps without this problem, you wont need to do this step.
Then, you have to sand the endcaps very well for getting smooth edges using sandpaper.
After that, take apart two endcaps and drill a hole in the top of them using the driller. We'll use a bit with the appropiate diameter, so the eyebolt will pass through the hole a little baggy. The perfect diameter for the hole is the same as the metal rings you have.
You need to cut the PVC pipe too. Cut two pieces of 33cm long approx. If it's too long for you, don't worry, you can fix it later. The end of this step is sanding the borders of the pipe.
Step 4: Mounting the Eyebolts in the Caps
Take one of the two endcaps with a hole and put a metal ring in each side of the hole you did. Then, pass the eyebolt trough it and adjust the secure nut. For adjusting it, hold the nut very tight with the pliers and spin the eyebolt. ATENTION: you don't have to stick the nut very tight, the eyebolt must spin free.
But relax! The secure nut is made for never coming loose, so the eyebolt will stay in his position in spite of the spin.
Step 5: Put on the "eyebolts Caps"
Take the two caps with the eyebolts on them and the pieces of PVC pipe. Before putting the PVC cement, sand the external side of the pipe as shown in the pictures, so the cement will act with more strengt.
Then, glue the endcaps to the pipes, one on each.
Step 6: Cutting and Fitting the Chain
Take the chain and cut a piece of 12 cm long approx using the tongs. Again, don't worry if it's too long or too short because you can fix it later after testing it.
I do not recommend to open the eyebolts for fitting the chain. The best option is to make a cut in each end link of the chain, open the link using two pliers and closing the link again when fitted in. Don't worry, the link won't open easily (I've used my nunchuks a lot an they didn't open even a little).
Step 7: Testing, Fixing and Putting on the Bottom Endcaps.
Before continue, NOW is the time to test the chucks. Be sure if they're comfortable to you or if they're not, because you can fix the length of the pipe before putting on the other endcap cutting a little more.
When you're done, put the bottom endcaps as you did whit the two endcaps of the top in step 5.
If you want, you can fill the chucks with something like a bag of sand, foam... but I do not recommend if you're going to use them for practising only and you're a beginner, like me. Believe me, they're strong enough and very hard, and making them heavier will make the thing more difficult for beginners and more painful.
Step 8: Add Details
This step is optional, because you have a functional nunchuks yet. But you can make them look better and improve them even more.
For example, I used duct tape for adding extra grip, for example.
Also, you can decorate them. I've drawed a pair of kanjis in the bottom with a black CD marker and then I've sprayed some varnish over them, but I'm sure you've got better ideas.
I use this cheap nunchucks a lot, and they're surprisingly hard built for its price, so if you've always wanted to have one of these, make them by yourself as shown. They're perfect for learning and training.
Easy to make, cheap, functional... They've got a lot of pros and I haven't found any con yet!
I'll feel very glad if you make one, and I'm very innterested in your opinion. Also, you can send me photos of your finished chucks, I'm sure they'll be awesome.
Thanks for reading, and sorry if i've commited any grammar mistake, I'm spanish and it's harder to me writing in english ;-)
Good luck with those nunchucks!
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