How to Make a Handle for a Rod

Rods have multiple uses, ranging from tool shafts to gear shifters. In the case of a tool, the rod forms the shaft. The top of the rod is capped with a handle to make positioning the tool a comfortable experience. Over time, a rod's handle will have to be replaced due to long-term use. Replacement handles can be expensive and extremely difficult to find. Use a few basic shop tools to make a rod handle, avoiding the cost of a replacement.

Measuring tape
Lumber
Straightedge
Jigsaw
Drill
Forstner drill bits
Electric sander
Sandpaper
Rags
Spray lacquer
Epoxy glue
Rubber mallet

Instructions

- 1
  
  Carefully measure the rod's diameter.
  
  Measure the rod's shaft. Accuracy is important. The shaft must fit tightly into the handle's base. Place a tape measure across the top of the shaft. Measure the shaft's diameter, writing it down on a piece of paper.
- 2
  Purchase the lumber. Choose a hardwood such as ash or elm. The width of the wood is dependent on the diameter of the rod. The width of the wood should be twice the diameter of the rod. If the rod is 1 inch in diameter, the width of the wood should be 2 inches.
- 3
  Lay out the handle's shape. Draw the handle's profile on the wood being used for this project. Use a pencil and a straightedge to create the profile. The handle should be large enough to be gripped comfortably when used.
- 4
  
  Cut along the line's outer edge.
  
  Cut the handle out. Use a jigsaw to carefully cut out the profile by following the drawn line. Cut just along the outer edge of the line. The jigsaw has an offset blade that leaves a rough cut edge. This edge will be sanded smooth later on.
- 5
  Mark the location of the rod's mounting hole. Turn the rough cut handle over so its bottom side is facing up. Using a tape measure, locate the center of the handle. This is the location where the hole will be drilled to mount the handle.
- 6
  
  Hold the drill perpendicular to the surface being drilled.
  
  Drill the rod's mounting hole. Use an electric drill to bore a hole slightly smaller than the rod's diameter. The hole should be 1/2-inch deep. Use a Forstner drill bit to create a cylindrical hole.
- 7
  Sand the handle. Mount 120-grit sandpaper onto an electric palm sander. Sand down the saw cut edges until smooth. Switch to 220-grit sandpaper, sanding the entire handle for 10 minutes. Finish with 400-grit sandpaper, sanding until the wood starts to develop a slight sheen.
- 8
  Finish the handle. Wipe the handle down with a rag. Use spray lacquer to seal the handle's surface. Hold the can 6 inches above the handle, making quick left-to-right passes. Apply at least four layers of lacquer, allowing 3 hours drying time between coats.
- 9
  Mount the handle. After the lacquer has dried for 24 hours, line the handle's mounting hole with epoxy glue. Place the handle's hole over the rod. Gently tap the handle onto the rod with a rubber mallet. Allow 24 hours drying time before using.

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