Hello Instructables Universe! I am a long time viewer and maker but this is my first actual 'ible. I found myself needing to do some hardcore sanding and my palm sander has mysteriously disappeared! Solution: Just attach a flap wheel on my angle grinder. Problem: Apparently the handle to my grinder and my palm sander are hanging out with all my socks from the dryer. So, to the drawing board!

Step 1: Tools and Materials

Luckily for me, the bolt that was part of the old handle was still attached. So I took some measurements and determined it was a M8-1.25 bolt. So after a trip to my favorite hardware store (read: any of them) I returned home with a matching set of bolts and lock nuts.

Parts:

M8-1.25 2.5" bolt and matching locknut

1" wooden dowel cut to about 5.25"

1- roll of self fusing silicone tape *

* I was lucky to find 8' rolls of this stuff for $1.27 each at my local hardware store, so I bought all they had

Tools:

1/2" spade bit

Tape measure

Glue- I used locktite go2 glue

Hacksaw, Hand saw, Circular saw, etc...

Drill

Patience!

Step 2: Measure and Cut

I lopped off a section of the 1" dowel about 5.25" long for a nice handle length, adjust to your needs.

Step 3: Drill

I used a 1/2" spade bit for this so it would be an extremely snug fit for my bolt. I drilled down about 2". As you can see its not exactly centered but thats okay, its a handle not a jet engine.