Wooden Tap Handles - by Ken Lenard
I have started playing with ways to make some sturdy, one-piece tap handles. Most of the ones I made earlier are in good working order but some have taken a jolt either from poor construction or drunken pirates pulling on them too hard. Although I have admitted to having little-to-no skill, I have found that I can handle a coping saw pretty well and that combined with a good power sander can get you pretty far. So I have fashioned some new handles and used a chrome ferrule with a screw instead of the larger faucet adapter I used in the past. Here is a sampling of some in various stages of construction. The "T"-shaped ones will probably have a different label on each side and also use the chrome finials I found at Kegworks and the others will probably just have a label on one side. These should be infinitely more solid than the others...
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I eventually picked up a cheap jigsaw ($35) and a cheap hand/palm sander ($25) and started making some pretty nice handles. I find images for shapes (if the shape looks too complicated, I find something simpler) and trace the shape onto the wood. Cut the shape with the jigsaw and sand the bejesus out of it with the sander (first with coarse paper and then fine). Then I drill the hole. This is the toughest part. I place the handle in a vice with the bottom facing up and just try to stand directly over the spot and make sure the drill is as straight as possible. I allow for a small amount of play, fill the hole with glue and insert the threaded rod or screw that has the right thread for the ferrule. If the glue is almost dry, I can screw on the ferrule and see if the handle will stand up straight. If not, I can slightly move it and then allow the glue to dry that way. Finally, prime, paint and design the label. Print out the label on high quality photo paper. Cut it out and fasten it to the handle with 3M Super 77 spray adhesive. Then hit the whole thing with a clear coat spray paint to ensure that the label doesn't run if it gets wet. I picked a lot of "beerglass" shapes to use but also made some oars, bowling pin, surfboards and other things. I have a summer blonde ale coming up and was thinking of making a handle in the shape of a flip-flop. Cheers guys.
Ps. Check out the surfboard with the shark bite. I just drew the bite mark in pencil (freehand) and then took the jigsaw to it at those angles. Came out better than I planned!
Ps. Check out the surfboard with the shark bite. I just drew the bite mark in pencil (freehand) and then took the jigsaw to it at those angles. Came out better than I planned!
