Asking for ideas to cap off mini-thor hammer handle

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Hi - me again with my hammers.Will post when I'm done but I'm 90% done on a small version of a Thor hammer - much smaller than my last. Used silicon bronze on the seams - really like how this is coming out.  Polished one face so far to a mirror like finish using a combination of things from a HF polishing tool and finishing off with the Benchmark abrasive's polishing paste/wheels - came out very nice - esp. the SiBz seams I hit.  Going to leave the weld bead ripples - not perfect dimes but I like the look - not going to grind smooth.But the handle - I just cut a piece of pipe - it's not threaded, thought about attempting to thread on a S.B. Lathe I have - then realized - while I have all the tooling - I have none of the knowledge of how to - so that will be a future project.  For now - this handle is just open ended - I don't want to weld a plug on the end - I'd like to make it removable as I am thinking of filling this with BB's or sand (then maybe choosing to dump out).  The I.D. of the pipe is 5/8" from what I mic'd - 0.62"  - thought about  internally threading with a tap then could screw a plug into place?  Even then use a 5/8" threaded rod and weld a smooth cap on the end?Anyway - just wondering if anyone else had any creative ideas - right now it's jus a smooth cut pipe!  thx
Reply:Machine up whatever fancy knob you want with a stub on it to a push fit in the handle. Drill it from the side, blind hole  with the stub in the pipe(more than one if your obsessive) drill out the hole in the pipe a bit over the size of the socket head set screw you are going to tap the stub hole for. Assemble and screw the set screw into the bottom of the hole. Use one long enough so that it engages the hole in the pipe but does not protrude beyond the pipe's outer surface.---Meltedmetal
Reply:Taking Melted's idea one step further... if you like working in sheet, why not make a shaped handle out of that as well? Thread the hole in the head and then all you need is a short stub of threaded rod to thread into it. Since it's all hollow, whether you fill it with beads or not is somewhat irrelevant to it's being used as a real hammer...it's all about the show.The harder you fall, the higher you bounce...250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
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Originally Posted by Meltedmetal

Machine up whatever fancy knob you want with a stub on it to a push fit in the handle. Drill it from the side, blind hole  with the stub in the pipe(more than one if your obsessive) drill out the hole in the pipe a bit over the size of the socket head set screw you are going to tap the stub hole for. Assemble and screw the set screw into the bottom of the hole. Use one long enough so that it engages the hole in the pipe but does not protrude beyond the pipe's outer surface.
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Originally Posted by whtbaron

Taking Melted's idea one step further... if you like working in sheet, why not make a shaped handle out of that as well? Thread the hole in the head and then all you need is a short stub of threaded rod to thread into it. Since it's all hollow, whether you fill it with beads or not is somewhat irrelevant to it's being used as a real hammer...it's all about the show.
Reply:I suppose you could drill the pipe with a larger side hole and put a cross bar in it like the things Ikea uses and screw the knob on from the bottom. Round rod threaded through the side.---Meltedmetal
Reply:Guess I completed the 'mini-hammer' for my son.  Maybe just will blue in his initials or something down the line.  Wanted to wrap the handle in leather, bought some 3/4" x 1/8" flat of it - but just couldn't get it to stay put!  So used the camo-paracord again. Pleased with the polishing results - used the benchmark abrasives #8 polishing kit suggested to me here on another thread.  Silicone Bronze for the seams - ended up fitting an experiment of mine from the lathe into the handle, tapping it from sides (as suggested above) and sinking the set screws flush with the handle into the brass plug.  Filled it with just over 2,500 steel BB's for some weight.




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Originally Posted by jfk92

Wanted to wrap the handle in leather, bought some 3/4" x 1/8" flat of it - but just couldn't get it to stay put!  So used the camo-paracord again.