Replacing a wooden handle means removing the broken stub from the tool head, shaping the new handle to fit the eye, and locking it with a wedge. It is a patient job with hand tools, and it can bring a favourite hammer or axe back into use. Follow the maker’s advice for your tool, and wear eye protection and gloves throughout.
Tools and Materials
- A replacement handle of the right length and eye shape
- Vise or clamp with soft jaws
- Hand saw, rasp and half-round file
- Hand drill or brace with a bit slightly smaller than the stub, or a punch and mallet
- Wooden wedge and a small metal wedge
- Sandpaper, wood glue and linseed oil
Removing the Old Handle
- Clamp the head firmly in the vise, protecting it with scrap wood.
- Saw off the broken handle close to the head.
- Bore several holes with the hand drill through the stub in the eye, keeping clear of the metal walls, then chisel out the remaining wood.
- Or drive the stub out with a punch and mallet, supporting the head so it cannot fall.
- Clean the eye with a file to remove splinters and rust.
Fitting the New Handle
- Compare the new handle with the eye. The top end is usually oversize so you can shape it.
- Shave the end with a rasp, testing often, until it slides in snugly.
- Cut a slot down the centre of the handle end for the wedge, as directed by the handle maker.
- Seat the handle in the eye by tapping the other end on a solid surface, rather than hammering the head.
- Drive in the wooden wedge, adding glue if instructed.
- Saw off the extra wood and add the small metal wedge across the grain for extra hold.
- Sand the handle smooth and rub in linseed oil.
Fitting Problems
| Issue | Likely cause | Remedy |
|---|---|---|
| Head wobbles | Handle not fully seated or loose wedge | Reseat, add wedge |
| Handle will not enter | Oversize end | Shave more wood |
| Crooked head | Uneven shaping | Check alignment before wedging |
Give the new handle time. Let the oil soak in for a day before heavy use, and check the wedge again after the first few uses in case the wood settles. Choose a handle made from straight-grained wood, such as ash or hickory, with the grain running along its length, since this resists shocks better. The maker of your tool may recommend a particular handle length and shape, so check that first.
FAQ
Can I reuse a cracked handle?
It is better to replace one. Cracks tend to spread under use.
How can I tell the handle is firmly fixed?
Check it before every use. If you notice any movement, stop using the tool and refit it.
The Short Version
Clamp, remove the stub, shape the new handle to a snug fit, wedge it and finish with oil. Go slowly, and check the head before each use.