I got this chisel with some others from Yahoo Auctions (like E-bay) a while back, I very much like this chisel, but the handle has two cracks in it, that were getting worse, the more I used it, so I decided that I'd try to replace the handle........ I've fixed a few hoops on handles before, but I've not completely replaced a handle........... until today.
I started with these parts........
I used some of the Sakura that looks a lot like Oak, to me, (this is still wood from the Tokyo Logging episode!) I rounded one piece and then took it to the drill press..........
I drilled a hole in the blank that was the same size as the square part of the chisel, that goes into the handle, this part is tapered, so I I took the measurement about half way up the shaft.
I then returned to the lathe and made the taper that the ferrel goes on, checking the size frequently.
Here is the ferrel in place, with the handle turned to final dimensions, sanded and even a little wire burning done.
The tang of the chisel is square, and the hole in the handle is round, so I did a bit of cutting with a small narrow chisel to get the hole somewhat square, but I was very concerned that if I pounded the handle on, I would have trouble getting it off, so I heated up the tang, just a bit, nothing near red hot etc, (I put a wet towel around the chisel to limit the heat transfer).
I then pounded the handle onto the tang.
I filed and then sanded the transition between the ferrel and the chisel body so they are smooth.
Here it is with the hoop installed. Now all I need to do is blacken it again, I understand that this involves just painting the shiny parts with salty water for a few days, and I'll get he nice back coating