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Make a wedge-style handle - PEP BB tool.sand.handle

BB tool care - sand badge
posted 5 years ago
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This is a badge bit (BB) that is part of the PEP curriculum.  Completing this BB is part of getting the sand badge in tool care.

Handles occasionally break and need to be replaced.  This BB is for the style of handle that will have a wedge driven in to hold the head on the handle.  

Examples of tool handles that qualify for this BB are:
 - axe
 - hatchet
 - maul
 - sledge
 - hammer
 - pick
 - pickaxe
 - pulaski

Split wood is generally better stock to use for handles but store-bought will work if you watch the grain (as mentioned in this video):


To get certified for this BB, post the following as pictures or a video (<2 minutes long):

  - tool with missing/broken/inadequate handle
  - new handle under construction
  - tool with new wedge-style handle installed
  - show the wedge after it  is installed

Clarification: store-bought replacement handles or blanks are not allowed
COMMENTS:
 
Mike Haasl
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posted 5 years ago
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I did this at the PEP1 event!  Not best handle but it's possibly the prettiest
Wooden-handle-and-hammer-head.jpg
Wooden handle and hammer head
Shaping-handle-with-shaving-horse-and-draw-knife.jpg
Shaping handle with shaving horse and draw knife
Shaping handle with shaving horse and draw knife
Finished-beauty.jpg
Finished beauty
Finished beauty

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Staff note (Mike Barkley) :

I certify this BB is complete.

 
Ken Mullan
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posted 5 years ago
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This is a handle I crafted for a sledge hammer at the PEP 1 course.
Sledge-hammer-head.jpg
Sledge hammer head
Sledge hammer head
Cutting-the-handle-to-size.jpg
Cutting the handle to size
Cutting the handle to size
Using-the-draw-knife-to-shape-the-handle.jpg
Using the draw knife to shape the handle
Using the draw knife to shape the handle
Shaping-the-neck-of-the-handle.jpg
Shaping the neck of the handle
Shaping the neck of the handle
Creating-the-slit-for-the-wedge.jpg
Creating the slit for the wedge
Creating the slit for the wedge
Fits-in-the-sledge-head-snuggly.jpg
Fits in the sledge head snuggly
Fits in the sledge head snuggly
Creating-the-wedge.jpg
Creating the wedge
Creating the wedge
Wedge-installed-and-cut.jpg
Wedge installed and cut
Wedge installed and cut
Finished-product-.jpg
Finished product!
Finished product!
Testing-out-the-sledge-on-a-log.jpg
Testing out the sledge on a log
Testing out the sledge on a log
Staff note (Mike Barkley) :

I certify this BB is complete.

 
Leif Ing
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For this axe head, I chopped down a Saskatoon standing dead pole/branch. I used a knife then a draw knife to peel, shape and smooth the handle. Then I split the end and made some wedges, put the head on and was a snug fit, then knocked a wedge in and finished it. Now Paul has a new axe with character for his tool rack!
Raw-handle.jpeg
Raw handle
Raw handle
Getting-ready-to-shape-the-handle.jpeg
Getting ready to shape the handle
Getting ready to shape the handle
Axe-all-finished.jpeg
Axe all finished
Axe all finished
Staff note (Mike Barkley) :

I certify this BB is complete.

 
Bill Anderson
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posted 5 years ago
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One of my favorite hatchets.
Hammer-hatchet-with-no-handle.jpg
Hammer/hatchet with no handle
Hammer/hatchet with no handle
Handle-in-the-making.jpg
Handle in the making
Handle in the making
Handle-smoothed-out.jpg
Handle smoothed out
Handle smoothed out
Handle-installed.jpg
Handle installed
Handle installed
Handle-finished-in-the-axe-head.jpg
Handle finished in the axe head
Handle finished in the axe head
Handle-pommel.jpg
Handle pommel
Handle pommel

Zone 8a Handicapped Gardener with crutches, sometimes a wheelchair

Staff note (Nicole Alderman) :

I certify this BB is complete.

 
Michael Holtman
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posted 5 years ago
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It's a bit rough, but I don't mind letting a giligan borrow this one with 30 seconds of training. The handle is made from a "scrap" of white oak that was found laying in a pile of MDF and other garbage. It still needs some oil, but it has already been put to work.
Starting-materials.jpg
Starting materials
Starting materials
Tools-used.jpg
Tools used
Tools used
Handle-in-progress.jpg
Handle in progress
Handle in progress
Finished-handle.jpg
Finished handle
Finished handle

"Now he called his name Noah, saying, 'This one will give us rest from our work and from the toil of our hands arising from the ground which the Lord has cursed." -Genesis 5:29 (NASB)

Staff note (Mike Haasl) :

I certify completion of this BB!

 
Dave Burton
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posted 5 years ago
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This is a hammer head that is missing a handle before I made a handle for it.



These are a few pictures of me constructing the handle.







This is the hammer with my finished handle that I made!



My handle stood up to the work that a hammer does pretty well!



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Staff note (Mike Haasl) :

I certify this BB complete!

 
Rob Lineberger
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posted 4 years ago
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I told Ashley that I'd give this hammerhead a handle, and here it is!







It's not *the* greatest handle in the world but the wedge seems to hold pretty well:



ETA:  Here is a followup of how this crude, yet very effective, hammer pulls a nail.

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Staff note (Mike Barkley) :

I certify this BB is complete.

 
Jordan Holland
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posted 4 years ago
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Made a handle for a carving hatchet.
20201024_214034.jpg
Roughing out hatchet handle
Roughing out hatchet handle
20201026_233656.jpg
Hatchet head needing handle
Hatchet head needing handle
20201026_234220.jpg
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Staff note (Mike Haasl) :

I certify this BB complete!

 
Opalyn Rose
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posted 3 years ago
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Here is my submission for the Tool Care - Sand - Make a Wedge-Style Handle BB.

I acquired this combination hatchet/hammer at a garage sale last summer and it needs some love.  I cleared the heavy rust and reshaped the blade edge with an angle grinder before removing the handle.  The handle was still stuck in the head but it had slipped out some and had also been damaged at the other end where you're hand goes - not comfortable to use this tool.  After I drilled out the handle, I soaked it in vinegar to remove the rest of the rust while I searched the oak branch pile for a new handle.  The drawknife, a belt sander, and the band saw completed the task of making the handle.  

To document the completion of the BB, I have provided the following:
  - pic of tool with missing/broken/inadequate handle
  - pic of new handle under construction
  - pic of tool with new handle installed
1.jpg
wedge handle tool
wedge handle tool
2.jpg
handle damage
handle damage
4.jpg
oak branch undergoing transformation into handle
oak branch undergoing transformation into handle
5.jpg
band saw cutting notch for wedge
band saw cutting notch for wedge
6.jpg
installing handle and setting wedge
installing handle and setting wedge
7.jpg
pounding wedge into place
pounding wedge into place
9.jpg
I kept about 1-inch of material above the handle instead of cutting it all off flush
I kept about 1-inch of material above the handle instead of cutting it all off flush

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Staff note (gir bot) :

Mike Haasl approved this submission.

 
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