It's really much easier than you would think!
Step 1: Supplies and Tools
1. Power drill (this is the only power tool required.
2. 1/4 drill bit
4. Handsaw, for wood
5. Hand file
6. 2 or 3 wood or c-clamps
1. Sandpaper, buy the assorted grade pack.
2. Wood for the handle. Use a hard wood like oak. It will last longer.
3. 3 inches of 1/4 round bar. They sell it at both Lows and Home Depot in 24" lengths
4. 5 minute epoxy
Step 2: Clean the Blade
the epoxy will not hold. It may be necessary to use a solvent to remove any grease or oil from this area.
Step 3: Preparing the Handle
Next, trace the blade on the wood. One for both sides of the of the handle.
Cut the handles sides out but don't cut on the line. Give your self some room to shape the wood to the blade handle. I used a jigsaw but the can easily be done with a hand saw too.
I used the existing holes in the blade. It actually had four but I only used three. I used 1/4" round bar for the pins. It's cheap and I like the look. The existing holes for the old handle were a little small so I used a 1/4" drill bit to enlarge them. Measure how thick the wood and blade will be when assembled. Cut three pieces to that length. Mine worked out to be 1 1/8" long.
Using the blade as a guide and drill the whole for the pins. Be careful to make sure they holes match the machete handle.
After the holes are drilled assemble all the pieces to ensure it fits together properly.
Step 4: Attaching the Grips the The Blade
Before opening the epoxy read the packing and instructions. You don't want to have to read them after mixing the epoxy. There is a reason it's called 5 minute epoxy!
I've found it easiest if you go ahead and start the pins in one side of the handle. Also have a hammer and the c-clamps close at hand. Once its all mashed together you might need a hammer to drive the pins all the way in.
While wearing latex gloves use some cardboard to mix the epoxy on. It won't take the whole tube but mix more than you thing you will need.
Apply epoxy liberally to both handle. Assemble the handle and make sure the pins are pushed through and flush on won side. Them attach the c-clamps hand tight.
I usually give the 5 minute epoxy at least 10 to 15 minutes to set before removing the c-clamps.
Step 5: Shaping the Handle
I like the use a belt sander to remove the larger area of wood. The same thing can be done with hand files. Once you get close to the shape you like start using the 80 grit sandpaper and then move to the finer sandpaper, 120 or 220 grit, to finish. When it is smooth and to the shape you like, there are many different colors of finishes you can apply.
I chose not to apply any finish. I like the look of the natural wood.k