I made a new timber hammer handle when the old plastic one broke. I used Merbau.

Besides saving the hammer head it was a good opportunity to try out my 2 new spokeshaves from the timber and wood show I bought recently. They went ok for $20 old recycled tools that arent particularly sharp or evenly ground or have much material left to regrind. Ive used better, and now I know what to look for and what to spend money on next time.  I think comfort and ease of depth adjustment are most important to me, as well as a razor sharp blade.

The Merbau was fairly easy to work, it did leave my hands stained black for about 2 days though. Cant imagine the dust is too healthy either.

http://www.timber.net.au/?option=com_species&name=Merbau&Itemid=441

To get the head to fit onto the new handle evenly, I was shown a trick whereby you tap the bottom of the handle on a hard (concrete floor) surface repeatedly to slowly wedge it on nice and evenly. As opposed to belting it in from the top down, possibly askew. I cut 2 wedges from the same timber as the opening at the top of the head was quite a bit wider than the bottom, and there was space to fill to create a tight fit.

I finished the handle with Carnauba wax, which I found really hard to apply even after heating it gently in the sun/with a heat gun. Maybe the tin I used was particularly old and dry?  Left a smooth but grippy finish filling up the grain nicely.

I wont use this hammer much as its a little too heavy for me for everyday stuff, but will come in handy when I need to belt shit hard.