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5K views 47 replies 14 participants last post by  DavePolaschek 
#1 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
 

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#2 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Interesting…..looks a bit uncomfortable…..

Flat scales, or maybe a chisel like turning?
 

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#3 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
I'm thinking flat-ish scales, rounded over, but we'll have to see what jumps out of the scraps pile. I might end up with something laminated out of thinner layers.
 

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#4 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
How about riveting the scales on? You already have one rivet hole and could create another on further down in the added piece. Might have to flatten the addition a little.
 

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#5 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Could end up doing that, Duck. I think a lot is going to depend on what I find for scales when I start rummaging tomorrow.
 

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#6 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Lemme guess, you were showing off, flipping the spatula in your hand after flipping the burgers, probably trying for two revolutions before catching it in you hand. Entropy takes over and it hits the floor (BTDT 8^)

It looks like you have it "in hand" Dave! Be interesting to see what you come up with after doing the knives.

Somehow I think your BBQ tongs and fork will meet a similar fate and require a matching rebuild 8^)
 

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#7 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Nothing so fun, Splint. I tossed it into the sink after using it, and it just snapped.
 

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#8 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
DP, now all you need to do is soak your hand in high concentrated water, so it'll shrink to be able to grip the new handle… love the thumb grip.
 

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#9 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Well you could do worse Dave,

Here is my effort after dropping my clamp on the concrete.

Road surface Bumper Automotive tire Asphalt Gas


Shoe Wood Thigh Human leg Event
 

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#10 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Not trying to be a spoilt sport, however,
Shoe Wood Thigh Human leg Nail


that's about how much a new spatula would cost in a $2 shop!
 

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#11 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Thanks, Rob. Nice work!

Ducky, most of my projects make little economic sense.
 

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#12 ·
Getting started

I have a spatula (or burger flipper) I bought decades ago that I really like. Not sure why, but the blade is heavy enough stainless that it works very well, both on a grill or in a cast iron skillet. It came with a plastic handle, and last week the handle snapped in half.

Kitchen utensil Wood Metal Composite material Rectangle


First step was to remove the last of the plastic. A 1 inch wide wood chisel and a vise grips were the tools, and it came apart pretty easily, but the tang was pretty short. I took a piece of 3/8" square mild steel I had and banged it around, drilled a hole, and riveted it on.

Kitchen utensil Tool Composite material Transparency Titanium


Wood Automotive tire Electric blue Rim Fashion accessory


That's enough of that for today. I've got four bookcases I'm finishing today too, and after I bring them into the house tomorrow, I'll mix up a batch of epoxy and join the steel to the stainless more securely. Cutting a cavity in a couple pieces of wood to get a good fit on this complicated shape might be tricky, so after epoxying the two pieces together, I may flatten things a bit with the grinder to make a simpler shape to cut in the wood. But I'm glad I extended the tang to give more support to whatever handle I decide to go with.
Ducky, most of my projects make little economic sense.
- Dave Polaschek
Now that I can live with DP... it's the misguided false economy that gets me questioning.
 

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#13 ·
Scales on, rough shaping

I started by carving openings in a piece of curly cherry to match the shape of the handle.

Hand tool Calipers Wood Office ruler Tool


Then I discovered the handle wasn't thick enough to carve to full depth without risking blowing out the wood, so I added a 1/8" thick piece of ash "veneer."

Wood Door Tool Household hardware Wood stain


Then I clamped the pieces together with some epoxy and poured a mix of epoxy and sawdust into the handle to solidify things.

Wood Tool Gas Electric blue Hardwood


After the epoxy cured overnight, I pulled out the belt-sander and did some quick and dirty shaping.

Wood Tableware Kitchen utensil Hardwood Wood stain


I could've used a drawknife or spokeshave, but using the belt sander gave me some fine sawdust. I used that fine sawdust to fill the last of the hole in the handle (dry), and then wet it down with CA glue. Not as strong as the epoxy and sawdust mix, but hopefully a better color match once it dries.

Wood Cylinder Gas Metal Soil


I'm a little disappointed I didn't get the scales on straight, but the diagonal stripe of ash may end up being a cool "design feature." Guess we'll see.
 

Attachments

#14 ·
Scales on, rough shaping

I started by carving openings in a piece of curly cherry to match the shape of the handle.

Hand tool Calipers Wood Office ruler Tool


Then I discovered the handle wasn't thick enough to carve to full depth without risking blowing out the wood, so I added a 1/8" thick piece of ash "veneer."

Wood Door Tool Household hardware Wood stain


Then I clamped the pieces together with some epoxy and poured a mix of epoxy and sawdust into the handle to solidify things.

Wood Tool Gas Electric blue Hardwood


After the epoxy cured overnight, I pulled out the belt-sander and did some quick and dirty shaping.

Wood Tableware Kitchen utensil Hardwood Wood stain


I could've used a drawknife or spokeshave, but using the belt sander gave me some fine sawdust. I used that fine sawdust to fill the last of the hole in the handle (dry), and then wet it down with CA glue. Not as strong as the epoxy and sawdust mix, but hopefully a better color match once it dries.

Wood Cylinder Gas Metal Soil


I'm a little disappointed I didn't get the scales on straight, but the diagonal stripe of ash may end up being a cool "design feature." Guess we'll see.
Looks good Dave. It is a cool spatula. Is it for the bbq?
 

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#25 ·
More shaping

Spent a couple hours today shaping the handle further. I started with a spokeshave, just eyeballing a comfortable shape.

Wood Tool Wood stain Gas Hardwood


Then on each end of the handle I marked guide-lines for a taper at the end, and cut to them with a knife.

Hand Fluid Wood Finger Tap


Then I used some 60-grit sandpaper to fair the sides and edges to the corners I'd cut.

Wood Rectangle Wood stain Hardwood Flooring


Going back to the knife, I trimmed the corners a little further.

Gesture Finger Thumb Nail Natural material


Then sanded again to get nice rounded edges leading into the end grain on both ends of the handle.

Wood Wood stain Trunk Flooring Artifact


And then finally used a knife-edge file (with a safe edge, so I wouldn't scuff the stainless steel handle of the spatula) to smooth the end-grain.

Wood Hardwood Metal Composite material Wood stain


That was it for the day. I dipped the handle in some tung oil, and once that's cured, I'll come back with some 120 and 180 grit and then another coat or two of oil.
 

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#26 ·
More shaping

Spent a couple hours today shaping the handle further. I started with a spokeshave, just eyeballing a comfortable shape.

Wood Tool Wood stain Gas Hardwood


Then on each end of the handle I marked guide-lines for a taper at the end, and cut to them with a knife.

Hand Fluid Wood Finger Tap


Then I used some 60-grit sandpaper to fair the sides and edges to the corners I'd cut.

Wood Rectangle Wood stain Hardwood Flooring


Going back to the knife, I trimmed the corners a little further.

Gesture Finger Thumb Nail Natural material


Then sanded again to get nice rounded edges leading into the end grain on both ends of the handle.

Wood Wood stain Trunk Flooring Artifact


And then finally used a knife-edge file (with a safe edge, so I wouldn't scuff the stainless steel handle of the spatula) to smooth the end-grain.

Wood Hardwood Metal Composite material Wood stain


That was it for the day. I dipped the handle in some tung oil, and once that's cured, I'll come back with some 120 and 180 grit and then another coat or two of oil.
OMG Dave I can see this Flipper ending up in the Smithsonian after we have both Karked it!

was the FA Kit needed?
 

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#40 ·
Wrapping it up

I started today by picking up the spatula and feeling where the handle didn't feel right. Mostly it was a matter of the corners needing to be rounded off a little more, so I got out the small HNT Gordon small spokeshave and started using it on the corners.

Hand tool Wood Natural material Tool Hardwood


I'm getting to the point where workholding can get challenging, but my big twin-screw vise is pretty handy for holding onto odd-shaped things, and by skewing it slightly, it holds the handle just fine while I'm fine-tuning the shape.

Wood Tool Hand tool Natural material Fashion accessory


After I got the bulk of the material removed (maybe a sixteenth at the thickest spot, but more like 1/32 or 1/64 in most spots - a little over a millimeter in the thick spots, and a third mm at the thin spots), I switched to abrasives. I used 120 and 180 grit, and then when everything felt good, the handle got another coat of tung oil thinned 50-50 with mineral spirits. It'll get all week to dry in the shop, and probably will get a second coat next weekend and then another week to dry. No hurry, as I'm not cooking many meals while I'm on jury duty.

Wood Rectangle Wood stain Hardwood Gas


I'll post the finished project in a bit with final photos.
 

Attachments

#41 ·
Wrapping it up

I started today by picking up the spatula and feeling where the handle didn't feel right. Mostly it was a matter of the corners needing to be rounded off a little more, so I got out the small HNT Gordon small spokeshave and started using it on the corners.

Hand tool Wood Natural material Tool Hardwood


I'm getting to the point where workholding can get challenging, but my big twin-screw vise is pretty handy for holding onto odd-shaped things, and by skewing it slightly, it holds the handle just fine while I'm fine-tuning the shape.

Wood Tool Hand tool Natural material Fashion accessory


After I got the bulk of the material removed (maybe a sixteenth at the thickest spot, but more like 1/32 or 1/64 in most spots - a little over a millimeter in the thick spots, and a third mm at the thin spots), I switched to abrasives. I used 120 and 180 grit, and then when everything felt good, the handle got another coat of tung oil thinned 50-50 with mineral spirits. It'll get all week to dry in the shop, and probably will get a second coat next weekend and then another week to dry. No hurry, as I'm not cooking many meals while I'm on jury duty.

Wood Rectangle Wood stain Hardwood Gas


I'll post the finished project in a bit with final photos.
Looks nice
 

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