Making overly ergonomic handle for rusty file - OLD TOOL RESTORATION
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I found this old rusty file for around 3 euros. It as a fair price as the file part costs easily 20 euros. It was a little quite rusty, the file was a little dull and the handle was made of cardboard for some reason.
Because the file handle the actual file is attached to, I does only allow one to use the file on one side there was no need to use straight handle which is no very comfortable . Because of this I designed a more ergonomic curved handle. On which I added a steel band with custom etched design to give it the extra style it needed. I also was orginally going to carve a checker design on the handle but as I found a piece of oak with the exact curve in the grain I wanted, that just felt like a little too much.
The steel collar was etched with electrolysis. I first used 1mm thick tape to mask my design then painted over it with just a basic primer and removed the tape to allow have only the previously taped areas to etch. You can find a lot of tutorials regarding this on the internet so I won’t be writing too brief instructions for for safety reasons.
I used vinegar to remove rust from the other parts of the file and after removing the handle. I had them there overnight which felt like enough. besides rust removal the mild acid bath will also sharpen the file. This is a simple and cheap way to give your old dull files a new life.
I used the freshly sharpened file to round the the part of the handle that fits the collar. I know there would have been easier ways but I wanted to do this to test out sharpened file. Plus how cool is it that I used the file to make a handle for itself An angle grinder and belt sander to sculpt the rough shape of the rest of the handle. A flap drum was used to finish the surface for an even finish. Then the collar was glued on with epoxy and the file was hammered in the hole of the handle.
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Music: Tobaggan - Silent Partner
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