This little guy may not be regulation, but he sure does look sweet.
Note: this Instructable is for people who are familiar and comfortable with the lathe. Do not attempt this if you have never used the lathe before. And always wear eye protection and a dust mask when operating power tools.
You'll need a lathe, a power sander, a wood blank (I used walnut), sand paper, and a drill press.
Step 1: Wooden Blank
The overall length of the broken player I had was about 4.25" long. So I cut the blank to 6" long to give extra material on both ends.
I recommend using square stock that is pretty close to square, it makes the next step easier.
Step 2: Drill Holes
Note: If you are making one of these for a particular table, you should double check the measurements of your table's rods and mounting screws before you drill the holes. You want the player to have a tight fit on the rod.
Step 3: Turn on the Lathe
I eyeballed most of the measurements for this guy, but there are a few you will need to make sure are correct. The distance from the center of the holes you drilled to the bottom of the player has to be 2.75" ( I based this off of the broken player). And the size of the bottom of the player should be .88" tall and .9" diam (again, I based these off of the broken player).
The rest of the form can be up to you, I found it helpful to use the actual Foosball player as a reference.
When the turning is done, sand it with 220, then 400, then 600 grit sandpaper.
Then cut off the excess using a small saw.
Step 4: Sand and Shape the End
Step 5: Add Finish
Now I just need to make another 21 of these guys to fill out a table.