Very often when I acquire an old hand plane, it’s not uncommon for the horn or end of the handle (tote) to be broken off. In order to remedy this, I fashioned a simple jig that allows me to make a clean cut on the subject handle using my table saw, to remove the broken end. The image below shows the jig with an old handle attached after being cut on the table saw. A hold down clamp keeps it in place while keeping hands away from the spinning saw blade. A couple spots of hot glue also helps to keep the handle securely in place.
After the broken end is removed, it’s a fairly simple matter to glue on a new piece of wood that can be shaped with into the same configuration as the original handle. In order to accomplish this task, I trace out the profile from another complete tote of the same size and type plane. The shape is initially roughed out on the band saw, and then shaped into its finished profile using rasps, files and finally sandpaper.
Since these old totes are made from Brazilian Rosewood they contain resin that will keep the glue from penetrating the wood and adhering. So before attempting to glue on a replacement piece, it’s necessary to clean off any mating surfaces. A good application of Acetone with a clean cloth or paper towel, right before glue-up should suffice. Acetone is also good for removing most, if not all of the original finish. I use Titebond brand Type I glue for this glue-up application. The image below shows two of the totes, with their new tops, after being smoothed with rasps and files. The handle at top left, in this image, has yet to receive its final shaping – it has only been roughed out on the band saw. The painter’s tape is used only for me to help keep track of which plane these totes belong to in accordance with my hand plane inventory system.
The original handles shown are Brazilian Rosewood which is an endangered species and thus no longer available. So unless you have some old stock or other broken handles laying around, you’ll need to use an alternate species to complete the refurbishing task. For this task I have used Bolivian Rosewood which is still readily available form most woodworking supply houses or hardwood dealers.
So now the fixes are complete. The image to the left shows the totes after their final shaping, sanding and finishing. I used Minwax Gel Hickory stain as it is darker than other Rosewood mimicking stains I have used. It doesn’t perfectly match the original 100 year old wood right now but in another 100 years after it ages no one will probably be able to tell the difference.
Here the finished totes are reattached to their original planes and ready to be used as seen here in the last photo below. Happy Planning!
