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How to replace a fibreglass handle?

Shop for Pavers Mauls

Use Epoxy resin adhesive to glue your new fibreglass maul handle in to place 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 

Secure paver's maul head in a vice and remove as much handle as you can with a fine toothed hand saw

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.

Use hammer and punch to remove remaining maul head

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.

Use a drill to drill out as much of the remaining handle out of the maul head

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

Insert the new fibreglass maul handle into the paver's maul head

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.

Seal gap around new fibreglass handle and maul head with putty or caulking cord before pouring in the epoxy resin adhesive glue

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.

Use caulking cord to seal gap around fibreglass maul handle 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.

To replace your maul handle, mix the epoxy resin glue according to the manufacturers instructions

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.

Pour the epoxy resin into the gap around the handle and maul head.

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.

Wonkee Donkee workman jumping for joy after repairing his paver's maul
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!

Wonkee Donkee says "Give yourself a pat on the back but try not to do it with your new maul!"