How to replace a fibreglass maul handle

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Things you will need:

Step 1 – Remove broken maul handle

Use a handsaw with a course blade (bigger, rougher teeth do a much quicker job than that of fine teeth) to cut away any remaining broken maul handle on the underside of the head.

Step 2 – Support maul head

Place the tool head in a vice if you have access to one.

This should be done in the same direction as the old handle would have been inserted.

Step 3 – Drill into maul handle

This may well go to plan, but if the remaining handle is in too tight then it will require some assistance.

Taking the drill and bit, drill holes in the fibreglass, either through the top or the underside, starting with one in the centre and a few around the edges as this should help release the pressure holding the fibreglass in place, ready to knock out.

Step 4 – Clean with sandpaper

Use the sandpaper to clean out any remaining debris in the eye, from the previous maul handle. This will also provide a rough surface for the epoxy glue to bond to.

Step 5 – Insert new fiberglass maul handle

Insert the bottom of the new handle so that the end sits flush with the top of the head.

Step 6 – Seal opening

Using the caulking cord (a putty type substance provided in your kit), seal around the handle where it meets the underside of the maul head. This stops the epoxy glue from leaking out before it dries.

Step 7 – Mix and check seal

Take the epoxy resin and mix both parts together as stated in the instructions.

Pour in a little of the resin first to check the seal. Should the caulk seal leak, you will lose all of your resin! To prevent leaking, push the putty further up into the eye.

Step 8 – Pour and allow to harden

Once the seal is secure, pour the resin, from the top, into the gap between the head and the maul handle.

Allow the epoxy resin to harden for the full amount of time, as stated in the instructions. If it does not set correctly, the maul may be unsafe to use.