Step 4: Shape With Sanding Disc on Angle Grinder

I have found that for removing large amounts of wood and shaping an object quickly, it's hard to beat a sanding disc on an angle grinder.  You can by all means carve the entire handle without power tools, but carving across the grain, as we had to do to create the rounded butt of the handle is very difficult.  The sanding disc does this work in no time.

The 80 grit disc removes a lot of material, so press lightly, make short passes and remove material bit by bit until you've shaped the handle.

Our two main handle features were 1) a rounded end to the handle and 2) a flattened top surface to rest our thumbs upon.  The flat top surface just gives the handle a little less of a massive look.  We made both of these features using the angle grinder, and then smoothed out the sanding marks on the stationary belt sander.

If you don't have these power tools, the same process could be done with a dremmel in just about the same amount of time.
<p>Wow. Epoxy on. Okay. I was waiting for the &quot;fashion an end plug page,&quot; but that is certainly more simple. Looks nice! I will be doing this for one of my spare portafilters for my 1976 Gaggia Baby Primavera (US market version).</p>
very nice! I love wood tools!
Very cool! My favorite thing about having a wooden handle on my portafilter is the way the wood feels, it's just much nicer than a hunk of plastic. <br> <br>My guess from the choices you listed for the wood is persimmon, as far as I know it's the only one of the four with dark heartwood.
Wow, this is incredible! <br />Amazing work and a perfect Instructable. <br /> <br />Also, do you think I could use bamboo instead? <br /> <br />GM
Are you envisioning a hollow piece of natural bamboo? Sure - you'd just have to fill the end with something if you didn't want a hole in the end of your handle. You could also laminate sheets of bamboo plywood (plyboo) together to form a block, then carve that down to shape. I bet the exposed cellular like structure of the plyboo would look very cool.

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