Making a Tool Handle – Part Two

To read Part One click here

If you are interested in buying one of these tools they can be purchased at Woodchuck Lathe Tools

My tools arrived today! I’m glad I waited before gluing the handle blanks together. Either my 1/2″ router bit is not exactly 1/2″ or 1/2″ square bar is not 1/2″. Either way the tool bar did not fit in the grooves I had routed. The depth of the grooves was fine, but the width was a hair to small. I increased the width fractionally on the router table and the fit was perfect.

Here is a shot of one of the blanks glued and clamped. I left the bar in the groove temporarily while doing the glue up to make sure the channel lined up nicely. As soon as I was done clamping, I pulled the bar out. I also marked on the bar the depth it receded in the channels. I know I will have some clean up to do in the channels due to glue squeeze out and I want to make sure the bar is able to fit in as deeply as it did during the dry fit.