Well, it's not a golf ball or a corn cob

[Dan_Shade]

Spent the day making a pile of file handles. 

Making the ferrules was the worst part. 

Doubling them up makes keeping the centers aligned when drilling the hole down the center. 

 

 

[Larry]

That's a good idea turning two at once.  I have a bunch of Hargrave I beam clamps that I need to replace the missing handles some day.  I'll file away your tip in my memory bank....never to be found when I need it. :D

[Dan_Shade]

It definitely helps to do two at once.

I used a unibit to deburr the copper. 

These are the steps:

1.  Make a template 
2   cut blanks to length for 2 handles, I left about 1-1/2" extra (this is not a requirement) 
3. Turn the handle to rough final form
4. Epoxy ferrule into place 
5. Turn/sand to final form 
6.  Drill centers out
7.  Separate the handles 
8.  Apply finish 

[SwampDonkey]

Pretty impressive. I have a project like that to do as well, for pull handles. The cords have to go all the way through, and pulleys. A whack of'm. ;D

Pulleys I've turned in the past, I turned them in 4's or 6's, cut apart on the bandsaw once sanded down.

[Dan_Shade]

I drilled a hole in a board to clamp the ferrules for deburring.



 

 

[Dan_Shade]

Here's the profile if anyone is interested.