Step 9: Clean up Mortise with Chisel

The drill press creates round holes, and like most mortises, we needed a rectangular hole.  Using a sharp chisel it takes only a few minutes to remove the remaining material to make way for the portafilter shaft and square out the corners. 

There are many more ways to make the mortise, including using only a chisel from start to finish or a mortise attachment for the drill press.  This was just the quickest and easiest way for us.

Keep removing material with the chisel until the mortise fits snug on the portafilter shaft.
<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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