9.4: Shaping the Handle
- Page ID
- 67208
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9.4 Shaping the Handle
The tool tote handle is made from one solid piece of hardwood.
The handle provides the main carrying surface of the project, but it is also one of the strongest visual elements.
Its shape should be:
- comfortable;
- strong;
- appropriate to the tote; and
- visually intentional.
Learning Outcomes
After completing this section, you should be able to:
- Select stock suitable for a solid handle.
- Design a handle that balances strength and appearance.
- Fit the handle into the risers.
- Shape the handle using appropriate cutting and shaping tools.
- Prepare the handle for final assembly.
Begin With Sound Material
The handle will carry the weight of the completed tote and anything placed inside it.
Choose hardwood that is:
- straight-grained;
- free from major cracks;
- free from loose knots; and
- large enough for the intended shape.
Avoid placing major defects in narrow or highly stressed areas.
Fit the Structure Before Final Shaping
The handle fits into notches at the tops of the risers.
Before finalizing the handle shape:
- Fit the risers to the box.
- Establish the spacing between the risers.
- Determine the actual handle length.
- Lay out the handle-to-riser connection.
- Dry-fit the structural parts.
This is another example of relative dimensioning.
The actual tote tells you the most useful final handle dimension.
Handle-to-Riser Fit
The handle is seated into notches in the risers.
The fit should:
- locate the handle securely;
- keep it centered;
- provide solid contact; and
- allow the parts to assemble without excessive force.
Final attachment will use glue and screws.
Your instructor will demonstrate the screw location, pilot-hole procedure, and assembly method.
Design the Shape
Once the structural fit is established, develop the handle profile.
Consider:
- hand comfort;
- thickness at the gripping area;
- transitions near the risers;
- overall proportion;
- grain direction; and
- strength.
Avoid making the handle unnecessarily thin in areas that carry load.
Make a Template if Helpful
A full-size paper, cardboard, or thin-sheet template can help you evaluate the handle before cutting the final hardwood.
A template makes it easier to:
- compare both ends;
- evaluate curves;
- adjust proportions;
- locate the grip; and
- transfer the shape accurately.
It can also provide a pattern if a handle must be remade.
Rough-Cut the Profile
Use the band saw or another instructor-approved method to rough-cut the handle.
Stay slightly outside the final line.
Do not force the blade through tight curves.
Use relief cuts when needed.
Refine the Shape
Refine the handle using tools appropriate to the form.
These may include:
- rasps;
- files;
- spokeshaves;
- stationary sanders;
- hand sanding; or
- other instructor-approved tools.
Work from coarse shaping toward finer refinement.
Shape by Feel
A handle is meant to be held.
Do not evaluate it only visually.
Grip it.
Move your hand along it.
Look for:
- uncomfortable sharp transitions;
- thin weak areas;
- flat spots;
- awkward changes in curve; and
- places where the hand naturally wants more clearance.
A small change in shape can make a large difference in comfort.
Leave Final Sanding for Later
Bring the handle close to its final form, but remember that it still needs to be fitted into the complete project.
Do not remove so much material that later adjustments become impossible.
Final sanding will continue during the finishing stage.
Check Yourself
- Why is straight-grained stock desirable for the handle?
- Why should the risers be fitted before determining final handle length?
- How is the handle attached to the risers?
- Why might a full-size template be useful?
- Why should you leave the layout line during rough cutting?
- Why should a handle be evaluated by touch as well as sight?