One of the go-to tools on my bench is a 1/8" thick Nicholson file. Sees regular use in several stages of call construction. I also have a few others that I use regularly as well. For years, I'd hack off a section of 1" oak dowell and drill a stepped dia. hole in it to hold the file. Fairly functional, but not exactly very nice.
I had some scraps that looked just right for making up some file handles and decided to make up some handles with them. While getting ready, I was trying to decide what to use as a ferrule. I had some high brass on the bench that I'd saved for another project (volume knobs on some guitars I was building) and thought it would make a great ferrule. I measured the inside dia and found it just happens to be exactly 3/4" too.
I started with a 6" long 1" turning square. This is Bolivian Rosewood. I use a lot of that for turning shift knobs for vintage sportscars.
To prepare the brass, I used a box knife to cut the plastic loose from the brass. I leave the plastic inside (a little worried about the glue letting go from that, but have not had a problem yet). I also poke the primer out. (Safety thing here. If you don't know what you're doing, don't do it. Get
)
Next up, I measure the tang of the file at several places. See what drill bits you have that match several locations. Mark the center on the blank and drill one end in a stepped fashion to make a tight fit on the file. I also end up using a reamer to get that last little bit sometimes depending on the file.
Next, I mark the centers and turn the stock round. Then turn a 3/4" tennon on the end. Turn the piece around and put the 3/4" tennon in my collet chuck. I turn the shape to fit my own hand. Good opportunity to make tools that are personalized just for you!
I should have turned a couple glue grooves on the tennon on this one, but forgot... For a finish, I used Hut friction wax as it seems to take a beating pretty well like it sees on the bench.
Finally, glue the brass on the end and prep it for the file. To prep mine for the file, I usually drill it with a narrow step bit, test fitting the file loosely as I go. Then you've got a finished handle ready for the file.
Here is one finished handle with a roundback file fitted.
I'm sure some others are doing something similar for their files. I hope maybe someone else tries this and makes good use of your scraps and some leftover brass!
