Japanese Chisel Handle Replacement

[Stuart Ablett]

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

[Stuart Ablett]

Oh yeah, one more picture...........


First characters "Best Quality"
Second Characters "Registered" This mean the blacksmith is a registered member of the black smith guild, and is licensed by the government.
Third is the name of the blacksmith.

[Frank Fusco]

Interesting job and nicely done. I'm not sure why you want to make it black except, maybe, just to restore to original (old?) condition. Salt water is cheap and easy. I have never heard of that technique. Phosphoric acid works well to blue/blacken. Urine is effective but takes time. A little late for that with the wood handle in place.

[Stuart Ablett]

Frank, thanks.

I understand that the blackening stops regular rust somewhat

Cheers!

[Frank Fusco]

Frank, thanks.

I understand that the blackening stops regular rust somewhat

Cheers!

True. I could reccomend some products, but believe they probably are not available in Japan. How did the old timers do it for tools there?

[Mike Henderson]

Thanks for the inspiration, Stu. I've always hated the standard handles on Japanese chisels but never tried to replace them. I think I will now.

I want a longer handle with a slightly different shape, and a rounded top that better fits into my palm. I hit my chisels with a wooden mallet so I don't need the hoop. And if I were to mash them up, I could make a new handle.

Was it hard to get the ferrule off the old handle?

Mike