{"id":46561,"date":"2026-07-25T09:00:00","date_gmt":"2026-07-25T16:00:00","guid":{"rendered":"https:\/\/kk.org\/cooltools\/?p=46561"},"modified":"2026-07-20T09:57:26","modified_gmt":"2026-07-20T16:57:26","slug":"gars-tips-tools-issue-213","status":"publish","type":"post","link":"https:\/\/kk.org\/cooltools\/gars-tips-tools-issue-213\/","title":{"rendered":"Gar’s Tips & Tools Issue #213"},"content":{"rendered":"\n

Getting a Handle on Things<\/strong><\/h1>\n\n\n\n
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Every tool has two functions. One is the job it was designed to do (aka the business end). The other is how it interacts with you, the user. Manufacturers optimize the first and often don\u2019t give enough thought to the second. For those with ability issues, it\u2019s often on you to buy or DIY a better human interface.

The goal isn\u2019t just comfort. A larger, softer handle spreads the force across more of your hand, reducing the amount of squeezing your fingers have to do. That means less pain, less fatigue, and, perhaps most importantly, more time spent making things than recovering from making things.<\/p>\n\n\n\n

There are all sorts of ways you can create custom, ergonomic handles. Here are a few approaches worth exploring.<\/p>\n\n\n\n

Foam Grip Tubing<\/h3>\n\n\n\n
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This is the simplest place to start. Occupational therapists have been recommending foam tubing<\/a> for years. The tubing slips over existing handles, instantly increasing their diameter while adding a layer of cushioning. It\u2019s inexpensive, easy to cut with scissors, and available in different sizes and colors. It works on everything from screwdrivers and paintbrushes to knitting needles, gardening tools, kitchen utensils, and pens. It isn\u2019t glamorous, but offers a real comfort upgrade for only a few bucks.<\/p>\n\n\n\n

Self-Adhering Wrap<\/h3>\n\n\n\n
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You\u2019ve probably seen the stretchy wrap used to wrap hockey sticks and other sporting equipment. That same material <\/a>makes an excellent custom tool grips. Add layers until the handle feels right to you. It\u2019s inexpensive, washable, and gives you complete control over the final shape. And when it wears out, you just remove and re-wrap. Self-stick bandage tape<\/a> also works. Here\u2019s a video of that approach<\/a> in action.<\/p>\n\n\n\n

Heat-Shrink Tubing<\/h3>\n\n\n\n
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For a cleaner, more permanent solution, consider heat-shrink grip tubing<\/a>. Slide it over the handle, warm it with a heat gun, and it contracts into a snug, durable covering. It looks surprisingly close to a factory-installed comfort grip and stands up well to regular shop use and abuse.<\/p>\n\n\n\n

Mold Your Handle to YOU<\/strong><\/h3>\n\n\n\n

This is where things get truly personal. Several products let you create a grip that\u2019s custom-shaped to your own hand.<\/p>\n\n\n\n

Sugru<\/a> is a moldable silicone putty that stays workable for about half an hour before curing into flexible rubber. Wrap it around a handle, grip the tool naturally, and your fingers create a perfectly fitted handle. The next day, you\u2019ve got something that feels as though it came from a custom orthopedic workshop.<\/p>\n\n\n\n

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Another option is moldable thermoplastic pellets, sold under names like Polymorph<\/a>, InstaMorph, and Polly Plastics. You just drop the pellets into hot water and they become soft enough to mold like clay. Here\u2019s a quick video<\/a> on making a basic handle with Polymorph.<\/p>\n\n\n\n

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If you have access to a 3D printer, there are all sorts of ergonomic handle designs<\/a> available online or you can design your own. Seen above is a set of ergonomic 3D printable handles<\/a> on Printables by Bryce Lowe<\/strong>.<\/p>\n\n\n\n

One of the great joys of being makers is that we have the knowledge and wherewithal to modify our environment to fit our needs. Our tools deserve the same attention. If a handle hurts, don\u2019t assume you\u2019re the problem. Redesign the handle.<\/p>\n\n\n\n

Have you modified a favorite tool to make it easier for you to hold? Did you invent a grip using something unexpected? Send me a photo and tell me what worked. I\u2019d love to see your solution<\/a>.<\/p>\n\n\n\n

DiResta\u2019s CNC Tips<\/strong><\/h1>\n\n\n\n
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I always love when Jimmy<\/strong> DiResta<\/strong> does these tips videos and he hasn\u2019t done one in a while, so I was thrilled to see this latest installment on CNC Tips. In it, he covers a broad range of tips, from the basic to \u201cwoah!\u201d-level ideas. Some of what he covers: Cutting a shallow placement outline into the spoilboard first, drawing the cutter diameter into your CAD drawing before machining to check for clearance, modifying the Z-zero plate with multiple stepped reference depths, using wedges for work-holding instead of elaborate fixtures, inspecting V-bits with a cheap digital microscope<\/a>, and raising or lowering Z-zero by a business-card thickness rather than immediately changing toolpaths.<\/p>\n\n\n\n

And my favorite of the video, a real \u201cWhy didn\u2019t I think of that?,\u201d marking \u201cTIGHT \u2014>\u201d<\/strong>\u00a0on your collet wrench.<\/p>\n\n\n\n

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