This is my 'ible on wooden tonfa. It is also my entry for the Epilog Laser contest. There are already several instructables on tonfa, but they were either PVC or steel.
***UPDATE*** I have since made another pair of tonfa, this time out of oak plated particle board tabletop. MUCH heavier; I can only imagine how painful this would be it you were hit.
P.S. Pics coming soon
Step 1: Supplies.
Dowel that you can get your hand around.
5/8'' thick wood.
Scrap wood (to practice on).
Brass pin (optional).
Step 2: The Design.
To determine the length of the blade of the tonfa, measure from your elbow to the tip of your middle finger and add one inch. Mark this on the 2x4. For me, that's 18". Now, lay your arm on the wood so that your elbow is about 1/2 inch from the end. From there, make a fist and mark where the center of your fist is. This is where the handle will go. The blade's width is equal to the 2x4's thickness. If you measure it, it's not 2 inches by 4 inches, it's closer to 1.5" by 3.5''. When I was done measuring, mine was18"x1.5"x1.5".
Step 3: Cut, Cut, Cut!
Step 4: The Handle.
Step 5: Cut Again.
Step 6: Drill the Blade.
Step 7: Head of Handle.
Step 8: Attaching the Head to the Handle
First, center the head on the handle. Use the 1/8'' bit to mark where the hole should be by putting it through the hole in the head and running the drill slowly. Drill about a 1/4'' into the handle. Next, line up the hole in the handle with that of the head. Screw the screw through the head and into the handle. Leave a small gap so you can spread wood glue on the handle. Tighten the screw completely. Let the glue dry for at least 18 hours.
Step 9: Putting It All Together.
For added strength, drill a small hole through both the blade and the handle. Cut the brass pin to just over 1 1/2'' long. Stick it in the drill and rough it up with some 100 grit sandpaper. Epoxy it into the hole. The pin should be slightly larger than the hole and should require gentle tapping with the hammer to get it in. Once the epoxy is dry, sand the pin down so it is flush with the surface of the wood. WARNING! EPOXY IS HIGHLY TOXIC. USE AT YOUR OWN RISK.
Have fun with your tonfa!