jdoolitt said:
Anyone else build the c-clamp handles from this shopnotes:
http://www.woodworkingtips.com/etips/etip030905sn.html ?? Not having a dowel handy, I cutup an old broom and made several of these one afternoon. Easy project - inspired by the cool c-clamps used by Bob and Rick on the show.
http://www.routerworkshop.com/Merchandise.html
Finding a chunk of soft rubber in this same size would be even better. Any ideas where something like that could be found?
On the first website I would try to improve by NOT notching the wooden handle.
(1)Instead drill out the center of the dowel to the correct ID and depth.
(2)Drill a hole in one side only at the correct measurement to meet the hole in the clamp handle.
(3)Place the dowel over the clamp handle and line up the holes.
(4)Drill out the far side of the dowel with your drill bit going through the clamp handle for perfect alignment.
(5)For a pin that won't fall out and so the new handle stay with the clamp I would get a drift pin (any 1/2 decent auto parts store will have these) that is a suitable size for the (metal) clamp handle and a wee bit shorter than the diameter of the dowel (file to length) if need be.
(6) If you want a rubber grip try to find some rubber garden hose, or low pessure discharge hose (NOT HEATER HOSE!) of the correct diameter to not quite slide over the dowel (maybe at that 1/2 decent auto parts store?). Place in boiling water for a few minutes (to expand the hose). (lets not forget our gloves here kids!) slide the hose over the dowel while the hose is HOT!!! and wet.
The result would be a handle that does not fall off. A slightly stronger handle but I still think a metal ring (much like the ring found on wooden file handles) around the hollowed out part of the dowel would be a good idea.
If you go with the rubber hose over dowel idea when the hose cools (contracts) and the water dries inside, it ought to have plenty of grip.
My $0.02.
CB