Making a custom handle from rough cut lumber isn’t as complicated as it seems. All you have to do is start with a game plan, take your time and go step by step. It’s a skill that still comes in handy when you need a replacement handle for an axe with an odd size eye or even if you just want a unique handle.
To begin with, you need suitable wood. Ash & hickory are the common choices but I’ve chosen to go with American elm. As well you’ll need to make sure the grain is oriented in the right direction and there is little to no runout.
Next, flatten and square one side to use as a reference. This will also allow you to trace out a handle shape to follow. The shape can either be drawn freehand or you can simply trace an existing handle that you like. Then saw or axe down to the pencil lines.
From there you can mark your handle width at 7/8″. I find that to be a good comfortable overall width but you can adjust it to suit your hands.
Now that your handle is a consistent width and cut to shape you’re ready to start shaping. Start by removing the four corners. Essentially making an octagonal handle. Then continue to take the corners off. Eventually, it will be close to an oval shape.
You are now essentially done. It can either left rough or smoothed with a card scraper or a fine rasp then finished with sandpaper. Generally, 220 grit is fine enough.
Overall the process isn’t difficult. It’s just a matter of time and practice. It’s something anyone can do with basic tools and is something everyone should try at least once.
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