Portafilter Handle Repair

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Introduction: Portafilter Handle Repair

About: Combining my woodworking with my photography/videography background is what I love, designing, making and sharing new ideas is awesome. This is fast becoming my full time job now so please subscribe and shar...

The portafilter handle for my ROK Espresso maker cracked from me being a bit overzealous with the knock box so I thought I'd just make a new one, a bit more fancy though : )

I used my lathe to shape the handle because it was quick and easy but you can use anything you like to carve out the handle. A jigsaw, bandsaw, carving knife or any type of sander will work just as well.

Using these methods or similar you can repair the handle on almost everything!

Step 1: Preparing the Stock

I have a bunch of scraps laying around the workshop so for this job I picked out some leftover ply that was cutout from the inside of a bandsaw box drawer I had made recently.

Basically the first step was to square up the timber close to size so that it fit in my lathe chuck. My table-saw and drop-saw made short work of this.

Step 2: Shaping the Handle

Shaping the handle on the lathe is pretty easy, I just made sure I took light cuts to reduce any tear out. I didn't really have a plan for the shape so kinda worked it out as I went along.

As mentioned earlier you can use anything you like to shape the handle. As long as it cuts wood it will work!

I then sanded the handle through grits of 80/120/180/240/320/500/1200. Finally I used some cut and polish to really give it a shine.

Step 3: Drilling Filter Basket Hole

Because I used the lathe chuck to hold the wood I still had a square part on the bottom of the handle that was inside the chuck jaws. (see step 4 for pic) This was perfect to use as a level base to hold the handle straight when drilling a hole for the filter holder. I firstly drilled a pilot hole then then the bigger hole, very carefully of course!

Step 4: Test Fit

My portafilter had a key on the filter basket that fit into the original handle and because I didn't need it I simply ground it off using my big grinder. I used my small rotary tool grinder to clean it up.

After test fitting the handle everything looked good so I then sanded off the square base using my disc sander.

Step 5: Handle Base

For the base of the handle I found a neat looking drawer pull at my local hardware store that matched perfectly. I just drilled a hole in the base of the handle so that the top off the pull sits flush against the handle.

Step 6: Finish & Glue Up

Once I was happy with the fit I gave the handle a few coats of poly then glued it all together. For this one the glue I used CA glue but I usually use epoxy.

Step 7: Photographs

And here it is, much cooler than the original i think!

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    18 Discussions

    I've also split my rok espresso handle, but don't have the equipment or skill you have. Any chance you'd sell a replacement handle? Seems crazy not to re-use the metal part.

    I guess technically it should be. Espresso is just hot water forced through the beans under pressure, right? I guess a food-safe and heat resistant pump plus a temperature-controlled water tank with some kind of interface with the handle thingy ought to do it. Then again, I have no idea how much water it takes, what temperature is good, and all that jazz.

    It never ceases to amaze me how pretty something like glued-together bits of plywood can be once they're sanded and polished properly. Beautiful work, and a beautiful handle for your portafilter!

    1 reply

    I hate being that guy but... Espresso not expresso

    1 reply

    Lovely, I am sure it adds to the aesthetics of making your coffee. a bit of caffeine and pride to start your day with.

    1 reply

    This is beautiful work, my friend.

    I agree with tomatoskins, the drawer pull is a brilliant idea! Your projects are very inspiring.

    1 reply

    I love how your handle turned out! I also like the drawer pull addition. Nothing makes me happier than using something not for its intended purpose!

    1 reply