Today we will be making a wooden lacrosse shaft that is usable in games under NCAA and NFHS rulings.
We will need:
A 2x4 that is at least the length that you want your shaft to be.
A table saw with a blade that can be adjusted to a 45 degree angle.
Stain if desired.
Step 1: Picking the Wood
The wood you pick is very important to your overall product.
First, the kind of wood. You want a wood that has a good balance of strength and weight. Some woods like Ash are extremely light, but may not be as strong or durable as you desire. Other hard woods can be achieved that are incredibly durable and strong, yet may be far heavier than you desire.
Also, I recommend using pine for practice. This process can be tricky to get down just right, and practicing with pine will help you to avoid messing up nicer, more expensive wood.
Next is picking your 2x4. First off, you don't have to use a 2x4. Technically, you could use an 8x12, but it would be much more work and much more wasted materials. In the beginning of this process your wood will be cut down to a 1 1/8" x 7/8" piece. This is most easily achieved by starting with a 2x4. Even thought any dimensions above 1 1/8" by 7/8" will work.
Your 2x4 should ideally be one that is a straight as possible, in good shape, and as free from knots as possible. The knots will mar and weaken the final product, and any curving may translate to the final product or result in uneven cuts.
Once you have your 2x4 selected, you are ready to proceed.
Step 2: Initial Cuts
The first cuts will be cutting down your 2x4 into a 1 1/8" x 7/8" piece.
First, lay your 2x4 down on its long side. Set your table saw to 1 1/8" distance. Make sure that this is the distance from the edge of the cutting guard to the beginning of the blade.
Now, cut the long side of the wood down to 1 1/8"
You should now have a 2 x 1 1/8" piece of wood.
Next, put the 2" side down. Set the blade to 7/8" again measuring from the edge of the saw guard to the beginning of the blade.
Now make the cut.
You should now have a piece of wood that is 1 1/8" by 7/8"
Step 3: Final Angled Cuts
Now we will be making our angled cuts.
Rotate your saw blade to a 45 degree angle.
All of these cuts will be made with the 1 1/8" side down.
Now set the cutting length to 1 7/8" This should be enough to take 1/4" in from each side. If your saw guard is not measured on this side there is another way to calculate your distance. With the blade angled to 45 degrees, Take your piece of wood and line it up so it is touching the blade. Line your saw guard up with the piece of wood with it still making contact with the blade. Now remove the wood and move the saw guard 1/4" closer to the blade. This should be ideal.
Now at this distance, make the cuts to each corner of the wood. The wood should now be in the shape of an oblong octagon (see picture).
Step 4: Final Touches
Now we will complete our final touches and aesthetic options.
You will likely want to sand down your finished shaft. This will give it a smoother surface and reduce splinters.
Another option is to stain or paint your shaft. This can be down with a variety of kinds of stains and paints, and its really up to personal aesthetic preference.
After this you are complete. Congratulations! You now have a legal and usable lacrosse shaft!