I keep a little "Box O' Shame" with small failures. I get this out to show people that yes, it happens to everyone. At least occasionally.
I had that happen to a gouge handle years ago, and learned to look at the grain first..... I pay close attention to grain in all my handled tools, shovels, splitting mauls, axes, and even hammer handles....
I read in an very old book about the traditional way to insure straight grain for strong tool handles.
- Select a fairly young hickory tree, straight trunk, no branches. Hickory with nearly all sapwood is good.
- Cut a log long enough for the longest handle. Best is freshly cut green wood which splits easily.
- Do not saw but rive with a froe smacked with a heavy wooden club, and a glut or two (wooden wedges). I read that gluts were traditionally made from dogwood. Apparently the heavy froe club/maul was also often made from dogwood so that's what I used.
- Split down the pith then split off pieces with enough cross section to make various handles.
- Put the pieces in the barn loft (to dry) and forget about them for a couple of years
I did exactly that and ended up with enough hickory to make a bunch of handles: axe, shovel, hammer, etc.
A friend looks for such trees and rives wood for steam bending and for shaping on a shaving horse.
Splitting along the grain insures high strength with the grain running the length of the handle. People also used to make boards this way.
This handle was for my favorite shuffle hoe. Easy to turn with a big skew. I use the "left hand" steady rest to control vibration. This handle "stretched" the capacity of my 3520b, even with the bed extension. I put the bit of detail towards one end so it didn't look like a store-bought handle. I sometimes took this to thin spindle demos to illustrate that a "thin" spindle doesn't have to be small - the length-to-diameter ratio is what matters.
This earlier shovel hand is a little under "regulation" length due to limitations of the lathe I had then. If ever repeating this, I might make a temporary stand-alone "extension" to hold the tailstock. A friend told me some people align two lathes end-to end for turning long things.
I had to search a while for a good froe. Finally found one for cheap at an antique store in Kentucky about 20 years ago. Had to make a handle for it but there are not side forces on it so the grain didn't have to be straight.
I actually found two. Made the handle and used the one at top. Doesn't need to be sharpened like a knife. The handle is used to guide and for leverage when splitting. The gluts extend the split easily.
The one with a wider blade would probably be used with a long handle. I gave that one to a guy I know who loves to sharpen things. Gave him a spare drawknife and several axe heads too, including a broad axe.
I also used a draw knife to shape a handle for an foot adze. (a relative had been using it as a weeding tool around her house). Some of those "traditional" ways to work with wood were great exercise. I think I had more energy 20 years ago...
JKJ