Wood handle with overmold and method of manufacture

1. A method of producing a tool comprising:

providing an elongated wood member shaped for use as a tool handle, said wood member having a first end, a medial portion and a second end;

placing said wood member into an injection mold cavity; and

injecting a molten material into said mold cavity to apply said material to said wood member medial portion and second end;

wherein said step of injecting a molten material into said mold cavity to apply said material to said wood member medial portion and second end includes the steps of:

applying the material in a molten state,

allowing said material to cool until said material is substantially rigid, and

removing said wood member from said mold; and

wherein said steps of providing an elongated wood member and applying the material in a molten state includes the steps of:

providing a wood member with a bore hole in said second end,

preventing said molten material from contacting said wooden member first end, and

wherein steam created from moisture in said wooden member during said step of applying the material in a molten state is vented from said wooden member via one of said first end or said bore hole.

2. The method of claim 1 wherein said step of providing an elongated wood member includes the step of:

providing a wood member with a moisture content of below about 10%.

3. The method of claim 2 wherein said step of providing a wood member with a moisture content of below about 10% includes the steps of:

kiln drying said wood member until the moisture content is between about 12% and 15%; and

air drying said wood member until the moisture content is below about 10%.

4. The method of claim 1 wherein said step of applying the material in a molten state includes the step of:

applying a layer of molten material that is between about 0.1 inch and 0.2 inch.

5. The method of claim 4 wherein said step of applying the material in a molten state includes the step of:

applying a layer of molten material having a thickness of about 0.125 inch.

6. The method of claim 1 further comprising:

providing a coupling device;

providing a tool head having an eye, said eye shaped to correspond to said wooden member first end;

inserting said wood member first end into said tool head eye; and

fixing said wood member first end to said tool head with said coupling device.

7. The method of claim 6 wherein said steps of providing a coupling device and fixing said wood member first end to said tool head include the steps of:

Providing a wedge; and

Inserting said wedge into said wood member first end.

8. The method of claim 1 further comprising placing said wood member into the injection mold cavity such that the bore hole is not enclosed in the injection mold cavity.

9. The method of claim 8 further comprising venting steam from the bore hole during said step of applying the material in the molten state to the wood member.

10. The method of claim 9 further comprising inserting a hollow tube into the bore hole to vent the steam.

11. The method of claim 10 further comprising:

removing the hollow tube from the bore hole; and

expanding the molten material at least partially into the bore hole.

12. The method of claim 1 further comprising placing said wood member into the injection mold cavity such that the first end is not enclosed in the injection mold cavity.

13. The method of claim 12 further comprising venting steam from the first end during said step of applying the material in the molten state to the wood member.

14. The method of claim 1 further comprising providing the bore hole in an end face of the second end.

15. The method of claim 1 further comprising providing the bore hole parallel to a longitudinal axis of the wood member.

16. The method of claim 1 further comprising injecting the molten material as molten polypropylene.

17. The method of claim 1 further comprising supporting the wood member by a plurality of pins in the injection mold cavity.

18. The method of claim 17 further comprising venting steam through a hollow pin of the plurality of pins during said step of applying the material in the molten state to the wood member.

19. The method of claim 18 further comprising:

removing the plurality of pins; and

expanding the molten material into vent openings from the plurality of pins.