DIY Angle Grinder Handle




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.


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


1/2" spade bit

Tape measure

Glue- I used locktite go2 glue

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



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.

Step 4: Insert Bolt and Locknut

Next i inserted the bolt with locknut almost all the way into the hole, filled with glue, and pushed the remaining length of bolt into the hole.

note: a hammer was used for "persuasion"

Step 5: Wrap Handle

Next I wrapped the entire 8' roll of self fusing silicone tape around the handle, stretching it a little as I wrapped it.

Step 6: Done!

That's it! Enjoy your new super grip grinder handle!



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    3 Discussions


    3 years ago

    Thanks guys!


    3 years ago on Introduction

    This looks like a highly suitable work around! Very nicely done!