Kevin Earle's Construction Method For Making Nunchaku
I made my first pair of Chinese nunchaku some forty years ago when they were not readily available, using the exact same method as I describe below - Kevin Earle
WARNING: In some jurisdictions the possession of Nunchaku or 2 sticks joined together is illegal. Penalties for possession may range from Fines to a term of Imprisonment. You are advised to check with your local law enforcement agencies before making or purchasing nunchaku.
LET'S GET STARTED
SIMPLE STEP-BY-STEP CONSTRUCTION
See Photos Below
STEP 1: Having shaped the shafts, drill the holes for the staples using appropriate size drill (in this example a 2.5 mm drill for the 2.5 mm wire). Position the first hole about 20 mm from the end of the shaft. (DO NOT drill the holes all the way through the timber - about half way should suffice.) Drill the second hole on the opposite side of the shaft about 40 mm in from the end.
STEP 2: Using your craft knife (or other suitable blade) form a 2.5 mm channel in a straight line between the holes and the end of the shaft, so that the staple will fit snugly with the surface of the timber.
STEP 3: Cut two 50 mm lengths of tubing for the sleeves.
STEP 4: Cut two equal (count the links) lengths of chain (about the width of your palm - longer or shorter depending upon your personal requirements).
STEP 5: Bend the last 10 mm - 12 mm of each end of the steel wire at a sharp 90 degree angle. Fit one end into the hole and channel on the short side.
STEP 6: With one end of the staple now in place slip one end of the chain over the staple. With your pliers bend the wire in a loop forming the staple, and push the other end into the long channel and hole.
STEP 7: Slide one sleeve over the chain and push and twist it over the end of the shaft, securing the staple.
STEP 8: Put the second sleeve on the chain.
STEP 8: Repeat steps 5 & 6 with the second shaft. Your second sleeve is already on the chain so simply push and twist it over the second shaft firmly securing the staple as in step 7.
STEP 9: Having finished the construction I recommend rubbing them with plenty of linseed oil, or olive oil. So long as you remove all the excess oil it will enhance your grip. Rub them with plenty of oil every few days, being sure to rub of any excess oil before use. The oil will soak into the timber over time, making the sticks heavier, as well as preventing splitting of the timber, and impact damage.
The staple should be shorter on one side than the other. Drill a hole the size of the wire you are using
Note that the staple is longer on this side. Use craft knife to form a channel to seat the staple securely
CONGRATULATIONS! YOU NOW HAVE A QUALITY WEAPON HANDMADE TO YOUR PERSONAL SPECIFICATIONS. ENJOY YOUR TRAINING!