I have found what I believe to be a T screwdriver, but half the wooden handle is missing. I can turn a new one and add the flutes but how do I get the square hole in the middle?????
Allan from down under.
1-Find a friend/furniture maker that still works in Imperial and who has a mortising machine.
The size mortising chisel bit is 5/16" (Imp). An 8mm would do.
2- Mail it to someone who does and ask them to plunge it for you. I have a mortising machine, but would have to check and see if I have a 5/16 cutting kit.
I could be wrong but I don't believe that there was originally a square hole in the handle. I believe that the hole was simply drilled and the handle then driven into it so that the compressed wood on the corners would serve as a bit of additional security for the shank. Sort of like a long carriage bolt shoulder.
I agree with RV. You will drill a round hole and let the square shoulders cut a nice tight fit. I would experiment on a couple scrap pieces of wood to find the best size round hole. You want a "goldilocks" fit "not too big, not too small" Then ad just a little glue and its as solid as you can get it.
If the end of the handle is "sharp", it will act as the cutters in the mortising machine--if they are dull, you might split your new handle. Just a thought, clamp the handle across the grain to prevent splitting.
Not having the proper tool you might try a small square file after drilling a hole to open the corners to fit.
Just thinking out loud but if the bored handles were boiled/steamed would they expand over the shank then shrink?? Bud.
I have a Jet Mortiser that bores square holes. I don't remember all the sizes it drills. I have about 6 bits.
Hey guys there is another way. You take a square piece of wood long enough and enough wide to turn the handle out of. You then simply cut it down the middle with as thin a blade as possible. You then route 2 grooves in the ength of it that are half as deep as your square shank is wide and as wide as the shank. You then take white glue and a piece of ordinary copy paper and glue the 2 halves back together with glue on both pieces but the paper in between as your sandwich filler. Let it all dry and chuck it up in your lathe and turn the handle out of the 2 halves glued together. When you have the shape perfect you then toss the handle into warm water and wait for the wood and paper to separate. Put the steel in without the paper and glue the halves together. The seam will disappear if you make the whole thing out of one piece of wood and put it back together exactly as it was cut apart. I made mine this way. I router table helps make it rather easy. Paint the handle black and install the steel ferrule and you are done.
John, I had thought of doing it your way, in two pieces. I was going to plough the cuts in the two halves by passing each piece over my table saw blade.
I will try the slightly smaller round hole and drive the shaft in method first and see how it goes.
Allan from down under.