I have been on a handle kick, and needed some handles for a bunch of files (tired of scrapping my wrist with the tangs). So this fits the bill and feels comfortable in my hand.
I started with the blanks of Oak (cut from stair tread drops) I varied the size by adding 3/8" to the thickness of the stock. This allowed for a nice flat spot on two sides, I then roughed the round just enough to remove the flat on two sides, saved some time since I did not have to adjust the tool rest until moving to the next size.
The sizes are, and each blank was a bit longer, and the smaller ones I turned 2 handles out of each: 6-1/2" with a 3/4 ferrule, 1-1/16" x 1-1/2" 5-1/2" with 5/8 ferrule, 7/8" x 1-1/4" (this size was added after I found out I needed some a bit larger) 4-1/2" with 1/2" ferrule, 3/4" x 1-1/16" 3" with 3/8" ferrule, 1/2" x 7/8"
I drew out some template halves to transfer marks to the blanks, and turned them down, making the ferrule a tad bit lose to allow for the epoxy. then sanded 100, 150, 220 and 320 followed by using the chips to burnish the wood. While on the lathe I did increase the grits on the copper and finished with 0000 wool. (Couple of catches with the wool, wound up right tight on that spindle).
After all were turned, I used a copping saw to cut them lose. Then it was a process of filing the ends smooth and finishing off the 3/8" round over. and a little sanding.
I then spent a little time masking off the wood so I could epoxy the ferrules in place. I have found that it is so much easier to remove the ooze out after it sets up a bit and before curing fully. Used a #11 Xacto for that, don't ask how I know.
After the epoxy set I set up for horizontal boring to drill a hole in the ends a tad bit smaller than what is needed for the tang. I wanted to have the ferrules in place first. Then wiped on a coat of Danish Oil and called them done. I will gradually set the files, for a good tight fit I'll heat the tang and burn them into the handles. My little setup for drilling.
Next up setting files, just a few. I will have a couple of extra handles. And I have a small set of needle files that I slip into a couple.
Thanks for looking and comments are always welcome and appreciated.
Be careful heating the tangs. if you over do it, you can ruin the temper of the file, at least near the tang. Personally, I have never liked the burn in method for setting the tang. I prefer to just epoxy them in.
--Nathan, TX. Hire the lazy man. He may not do as much work but that's because he will find a better way.
Nathan, thanks. I wasn't sure about the temper but will keep that in mind. I was thinking about the ferrules being epoxied and braking that down with a burn method. I could enlarge the holes a bit and step for the length.
I’ll second what Nathan said. I either press them on or use some hardened steel spring-like metal screws just like the store-bought screw-on file handles. Don’t remember where I picked them up, but I like the metal inserts better than the plastic inserts I used to use, and you can unscrew the handle and reuse it if you happen to wear out the file.
The other thing I have is a piece of tool steel a buddy back in MN cut to match the two sizes of file tangs I had. I can heat that up over and over if I really want to burn handles on. He made one for the two sizes of Mora knife blanks I use most, too. But I don’t think I’ve burned a handle in since moving to NM.
Very Nice Eric...Good progress pictures...The ferrules fit nicely too. Stair Tread drops will be nice and strong and solid. (The Oak Wood is very nice) Regards......Cliff.
Cliff, thanks. The ferrules were a bit tricky, had to take a bit off and size, take a bit more and repeat a few times for each one. The Oak should work nicely. And using up some of the free scraps in the shop.
Mike, thanks. I may just press fit them too, maybe a little persuasion with a hammer. That is one nice thing about the site here, you get ideas and causes you to go to the shop.
Ryan, thanks. Just a needed project.
OldTool, thanks. The simple design is easy and those flats are required on some tools in the shop.
Ron, thanks. The shop time this past week, Tried to make it productive. And efficient handles are a must.
OldRivers, thanks. The shop has been up and running for 2 years now and still adding to it. but having fun doing it.
Petey, thanks. No place on the wall or tool board. Need to build a drawer to add to a cabinet which has empty spaces for about 4 or 5 drawers. I started it 2 years ago. It is the case with 4 in it now.
Jim, thanks. Lots of turning, but it helped me refine my turning skills, not a master but better. And for shop tools they did not need to be fancy.
