How to make a shock-resistant tool handle from a plastic canister

Files, chisels, screwdrivers and knives with wooden handles often become unusable due to the wood splitting from swelling or impact. HDPE handles, which you can make yourself, are much stronger.

What you will need:

• plastic canisters and other products labeled HDPE;
  
• tin form;
  
• bake;
  
• lathe.

Handle manufacturing process

To cast plastic handles, you need to prepare raw materials. Plastic cans or other products labeled HDPE are suitable for this. The plastic is cut into pieces using scissors. If you need to make a one-color handle, then you need to use canisters of the same color.

Next, a tin mold for the handle is selected. Tin or aluminum cans and bottles are used for this. You can use a deodorant can. It is advisable that the form be larger than the required size. This will make it possible to grind off excess plastic and straighten the handle if the tool hardens in it with a distortion.

Next, the plastic is placed in a mold, and it is placed in an oven with a temperature set at 320 degrees Celsius. It is necessary to check periodically so as not to miss the moment when the plastic begins to leak. It is important not to overcook it so that it does not burn.

The mold is immediately removed, and the pieces of plastic in it are forcefully compacted with a wooden handle or metal round timber.

After compaction, the volume will decrease, so new plastic is added on top and the mold is returned to the oven. The process of heating and compacting is repeated until the mold is completely filled with a dense mass.
The tool shank is inserted into the complete mold. It is advisable to make notches on it for better grip. After cooling, the mass shrinks and compacts well.

Next, you need to tear or cut the mold and remove the workpiece.


The tool with handle is clamped in a lathe and turned to an acceptable shape.

If you don’t have a machine, you can roughly cut it with a hand tool and then sand it by holding it in a drill chuck. The remaining shavings can be reused. If potholes remain in the handle, then this indicates a weak tamper. In the future it should be done better.

The finished HDPE handle is impact resistant and holds up very well. Therefore, the tool will serve with it for many more years. She is not afraid of water and is pleasant to the touch.

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