Introduction: Portafilter Handle Repair

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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of Photographs

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

Comments

SamK105 (author)2016-07-19

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.

kakashibatosi (author)2014-11-28

Fun handle! Now I just need an 'ible on how to make an espresso machine XD

Thats a great idea, I wonder how possible it would be. Even a scale model would look cool though.

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.

susiefreckleface (author)2014-11-28

absolutely beautiful.

Cool, glad you like it!

jjdebenedictis (author)2014-11-27

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!

Many thanks, ply is underrated : )

Shkinball (author)2014-11-27

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

Thanks, yes I dont know why I keep spelling it like that..grrrr

Kafukai (author)2014-11-27

Nice :-) I like your table saw method, I allways scare to use it on small pieces.

Cool, cant hurt yourself if you are nowhere near the blade..

Ultra-Indigo (author)2014-11-27

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

Yep exactly!

seamster (author)2014-11-27

This is beautiful work, my friend.

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

Thanks! : )

tomatoskins (author)2014-11-26

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!

Thanks! Yes I've used the drawer pulls on a few different things, in different ways : )

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Bio: 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 ... More »
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