I have a TrueTemper 6lb maul I bought in 1991 that I wore out the handle on. I went to the local hardware store and grabbed a maul handle. When I looked a bit closer at my maul head I realized it needed an oval handle like would fit a sledge hammer. I went back to the store and found the right handle but it is slightly too big for the opening in my maul head. The shape of the handle looks perfect, but just too big. The handle is Hickory. What would be the easiest way to get that handle small enough to fit? Pics in the morning. Thanks for your input!
Sharp hand tools (knives and rasps) are the traditional way. Drawknives and spokeshaves work well too and I use them on lots of things, but they are not common items these days. About 10 years ago I started using a cheap (like $12 on sale) Harbor Freight 4-1/2" hand grinder with a cheap ($3-4) flap sanding disk. About 80 grit works well, but 36 or 100 would work, depending on how much speed vs. control you want. The thing I like about this setup is that it's cheap, is handy for working on everything from wood items to boot soles, and is easy to control. You can sand very fine amounts easily with a light touch and get a nice fit. Good luck!
You made me think about when I was a kid and my dads workbench in the basement. He was a finish carpenter/ cabinet maker before all the pre-fab stuff forced him into other work. He had every hand tool you could imagine. I have a harbor freight angle grinder. I will have to look and see if I have any flap discs. If not I can get some easy enough. Good call! Thanks much!
I have used an angle grinder with a standard grinding wheel too. Also, a bench grinder...both worked fine...the key is to take your time and not take too much material off at once...grind, trial fit, grind, trial fit, grind...
It's going to be a bit awkward for me since I don't have a vise. I ordered some flap discs as I need them anyway. I might try a combination of both. Use the grinding wheel to get it close then the flap disc to clean it up and finish it off. We'll see as I plan to start fooling with it today. I need my maul to do some splitting.
I do mine sitting, holding the handle across my lap with my left hand, with light strokes with my right moving away (towards the head end of the handle), sort of a brushing/sweeping motion. You just roll the handle with your left hand as you work around it. That's a lot faster and more natural than constantly repositioning in the vise, and it makes it easy to take small amounts at a time. Try it a few times with the grinder off to get a feel for the motion.
