Swapping wooden chisel handle to plastic
auschippy92
| Posted in General Discussion on
Hey guys recently purchased a wooden bench chisel but made the mistake of not knowing they are to be used with a mallet not a metal hammer . Is there any way to swap the blade to a plastic handle ? I would just swap chisels in store but the blade quality is un real on this particular chisel
Replies
It's difficult as the best plastic as used in most handles is not so easy to get.
Cellulose acetate is commonly used for handles, and as a thermoplastic can in theory be melted and re-cast, then finished if needed on a lathe. It is usually only available as granules, film or old chisel handles so would have to be cast. I would not waste my time doing so. I could not find a youtube video showing this so it is quite likely that it is a particularly big ask.
If you were really keen to make handles, then it might be fun to try melting toothbrush handles. These are made of polypropylene (same as coke bottles - edit - these are polyethylene - many lids are PP - no5 recycling symbol) and are recyclable but generally just get chucked. PP has good impact characteristics and is very readily available in household items for free.
Your best bet would be to find a metal ring that is slightly smaller than the end of the handle. File the end of the handle to accept the ring with a very tight fit. Epoxy will hold it in place, but if you feel fancy, you can heat it up so it expands and will fit over an oversize spot on the handle. I find that 22mm copper pipe works well.
To be honest, what you hit the chisel with is not really that relevant. What matters is how sharp it is. Whaling on a chisel will chip the handle regardless of the hammer used.
The main reason most of us use wooden hammers is that they are much larger for the same mass, thus permitting a larger striking surface - this helps with control and makes missing the end of the chisel harder. There is of course the old adage of less damage to handles, but I can't say for sure that this is true (or that it isn't for that matter)
I use a flat-faced beech mallet though many others prefer a turned round one. If I am feeling lazy, I will use a claw hammer betimes, and have yet to damage a handle with it.
The only handle I have with a ferrule is for fence posts!
Why not buy a wooden mallet and try that if you truly love your chisel.
Some chisels have handles that are extremely easy to swap out. Some are not. It's hard to say which yours is. If it's a new chisel, I would say the odds of getting a replacement handle from the manufacturer is close to zero. I've never seen aftermarket plastic chisel handles being offered. Lots of places sell wood handles though.
Show us a picture and we can offer more. But chances are, your handle is epoxied on.
Start by removing the old handle by splitting it on the grain to see what the tang is like. You can buy plastic bar and rod stock from suppplers like McMaster Carr. Most plastics work well with woodworking tools if you are careful about heat.
Cheers for all your input , making a plastic handle sounds like the best option as carrying a mallet and claw hammer on my belt would be a nousance , have taken apart the handle which was easy enough without damaging it, here's a couple photos .
Why not just make a mallet?
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