A fibreglass handle is fastened into place with epoxy or a similar resin rather than with a metal wedges as generally used to secure wooden maul handles. You can also use epoxy for your wooden handles.
Removing the old fibreglass handle
Step 1 – Secure in vice
Secure the maul head in a vice to protect the head. Use a fine-toothed hand saw to cut off the old handle as close to the head as possible without damaging it.
Step 2 – Remove remaining handle
Remove the remainder of the handle from the eye of the head with a hammer and a punch or a large bolt. This should ease out after a few taps with the hammer.
Step 3 – Loosen stubborn pieces
To loosen a stubborn piece, use a drill with a 6mm (¼ inch) drill bit and drill through the wood. You may need to drill several holes to remove a rigid piece. Use a hammer and punch to drive out the remaining handle and file away any shards of fibreglass.
Once this is removed, clean the eye of the head and remove any debris.
Fitting the new fibreglass paver’s maul handle
Step 4 – Insert handle
Make sure the eye of the paver’s maul head is clean. Epoxy will not bond to greasy or rusty surfaces. Insert the handle core into the head until the top is flush or aligned with the head. You may need to file down the handle to fit.
Step 5 – Seal handle
Seal the gap between the handle and head with putty or caulking cord to keep the epoxy from leaking out. The putty or caulking cord should be pressed right up against the head to form a tight seal.
Caulking cord is a putty-like strip of material used primarily for sealing drafts in windows.
It is usually sold in long, rope-like rolls, which can be cut to the desired length.
Step 6 – Mix epoxy
Check the instructions supplied with the epoxy for correct mixing as this may vary from packet to packet. Mix together the contents, gently to avoid the formation of air bubbles, thoroughly ensuring a uniform consistency and colour. If it is not blended properly, the epoxy may not cure correctly.
Temperature affects the curing process of epoxy, so read the manufacturer’s guidelines carefully.
Step 7 – Apply epoxy
Apply the epoxy between the top of the new handle and the paving maul head. Ensure that the handle remains correctly aligned at all times.
If epoxy leaks out from around the caulking cord seal, reseal by pressing the sealer firmly into any gaps.
Wipe off excess epoxy, storing the maul upright to prevent leakage. Leave the epoxy to fully cure (or harden) for up to a week before using the maul again.
Don’t forget, practice makes perfect and be proud of your workmanship!