Fix for cracked ball end handles.

[Brian S]

There's probably a more than a few of us with cracked ball end Gillette handles. I had one and I used the threaded ferrule to create a new handle seen here- http://badgerandblade.com/vb/showthr...rew-NEW-handle

After making the first one I had some material left over and a spare NEW head with no handle so after our member Windrider sent me another cracked ball end handle for parts I came up with a quick fix that doesn't need many tools or expense.

Go to the hardware store, I checked several ACE stores and a mom-n-pop locally and they all stocked the item you need to buy. What you need is a 3/8" brass tube, they sell a length of about 12" for around $4.50.

Pop out your old ball end and threaded end from your cracked handle.

Cut the new tube to the correct lenth or whatever length you like (I like them longer).

You can weight the new tube with something or not, your choice (I used melted lead).

Before you assemble this is a good time to think about any finishing you plan to do. The one in the photo was simply stripped of all the old gold wash on the ball end and ferrule end, the tube was polished with a Dremel tool, the ends were masked and a rough finish applied by LIGHTLY running a sanding drum over the exposed tube area. I have another in the works that will be all brushed finished.

Use good adhesive to glue the ends in and clamp together for however long you need to. Be sure you don't get any into the threads.

TIP- you can easily cut the new tube with a hacksaw or cutting wheel on a dremel but a real tubing cutter will give the ends a slight crimp which helps to perfectly center the ends in the tube when you are ready to assemble.

Here are photos of my first attempt. It is longer and much heavier than a factory style ball end handle and sure feels more substantial in the hands.
Thanks to member Windrider for the parts to do this project!

[HoosierTrooper]

Brilliant!

[windrider]

Way to go Brian!! Wish I was that clever. Think I'll give that a try. Now, if I just had a handle with a crack in it.

[Sledgehammer39]

Man that looks great!!

[TheGRman]

Genius! My three ball-end tech's are nickel plated, so I wonder if a 3/8" aluminum tube would work instead of the gold-toned brass tubing? Guess I'll have to make a trip to the hardware store and investigate. Thanks for posting this.

[natchez]

Very, very clever! Thanks for the tip.

[Brian S]

Here's the second version, this one is satin and polished. The ball end got the knurling removed also.

[Brian S]

Genius! My three ball-end tech's are nickel plated, so I wonder if a 3/8" aluminum tube would work instead of the gold-toned brass tubing? Guess I'll have to make a trip to the hardware store and investigate. Thanks for posting this.

Worth a shot, I didn't look at the aluminum but they did have stainless steel.

[Doryferon]

Well done Brian!