Inserting the Tang and Finishing the Handle

Some use epoxy to fasten their handles - I've not found it necessary unless the tang was poorly fit into the handle (though it is handy to have as an option!).  Rather, I've found the old way of inserting a tang to be both effective as well as the simplest.  Heat.

Some have voiced concerns to me that heat will ruin the temper of the tool - I've not found that to be a problem, as I only heat up the tang, and not the tool.  It doesn't hurt if the tang is not as hard as the rest of the tool, as it's not doing the cutting...  So - with that all settled...

I use a propane torch to heat the end of the tang up:

I avoid using the torch near the tool, for the reasons stated above.  As long as the tang is hot, it will do it's job.  It should be close to being red hot, though you probably won't be able to tell unless you turn the lights off.  When you insert the tang into the handle, it will smoke a bit letting you know it's working.  Drive the tool into the handle about 1/8" short of the bolster with a wooden mallet - excessive force should not be necessary, as the heat from the tang will burn it's way into the wood and seat the tool.  Again, work quickly, as the tang will cool and lose it's 'cutting' ability:

Once you are within 1/8" or so of the bolster, remove it from the wood and let it cool or quench it.  Then replace it in the handle and drive it home the last 1/8" to get a firm seat.

And there it is!  The handle is installed onto the tool.  All that's left now is to cut off the 'base' left on the handle from turning it on the lathe, sanding it, and finishing it.  I saw the 'base' off with a back saw, rasp or file the edges left till they are smooth, and finish sand the entire handle before applying a finish.

For a finish, I put on at least two coats of boiled linseed oil, and when that's dry I'll put on a couple coats of thin shellac - around a 1# cut or so to keep the dirt and sweat from sticking to the handle.  Here is a shot of the handles done for this project:

A closer look:

The two on the right are a pair of cantsaw files I bought for a special project I'm working on.  Those handles are hickory glued together from the scrap pile.

Great fun.  I have yet to see if I like the shape of the handles, but they seem OK so far...

Thanks for reading!