How to Make a Tonfa Out of Wood

Cheap, factory-churned martial arts' weapons are often the first type a practitioner uses. But they are usually made of inferior materials and not sized appropriately for the user. The best weapons are those made carefully from good materials and fitted to each individual. A tonfa is a nightstick-shaped weapon with a handle to grip and a shaft that protects your hand and arm. Proper size and weight as well as durability makes a world of difference in practice and use. This will allow you to progress further and become more skilled than when using an inferior weapon.

Things You'll Need

  • Wood, 2-by-2-inch and at least 36 inches in length
  • Measuring tape
  • Sandpaper
  • Chisel
  • Plane
  • Drill
  • Saw (table, band or hand)
  • 4-inch flathead wood screw
  • Wood glue
  • Wood putty
  • Wood varnish
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Instructions

  1. Select the Right Wood

    • 1

      Take measurements of your hand and arm to determine the correct size for your tonfa. The grip will be the width of your hand plus 2 inches. The body will be the length from your elbow to fingertips plus 1 inch.

    • 2

      Find a suitable piece of wood. Ash, hickory, or oak woods are preferred for density and durability. The grain should be tight and smooth with no knots to prevent cracking and splitting.

    • 3

      Choose a piece of wood as long as the body and grip measurements plus 2 or more inches.

    Make the Tonfa

    • 4

      Cut the length of the body from the main piece.

    • 5

      Use a plane to taper both ends on the side the handle will attach to. The end that will be closest to the handle should be tapered 1/4 inch or less over a 2-inch length. The opposite end should be tapered 1/4 inch over an 8-inch length.

    • 6

      Sand the wood gently. Slightly blunt the corners and edges.

    • 7

      Cut the remaining piece to form the handle. Use a chisel to shape the handle. The handle will be circular when complete and there will be a slight knob on the outside of the grip.

    • 8

      Sand the handle and knob until smooth. It should look like the bottom grip of a baseball bat.

    • 9

      Drill a hole on the main part of the body. The hole placement measurement will be the distance from the center of your palm to your elbow. Center and countersink the hole.

    • 10

      Drill another hole on the end of the handle that will attach to the body.

    • 11

      Varnish both the handle and body. Apply a second coat if necessary.

    • 12

      Place a small amount of wood glue around the edge of the handle within the predrilled hole. Attach the handle to the body with a 4-inch wood screw.

    • 13

      Cover the screw head with a small amount of wood putty if desired. Sand lightly after the putty has dried.