I'm trying out Hypalon grips for the first time, and need to shape them. Before I start shaping, I thought it would be prudent to ask for advise first. Can anyone share any special concerns with this material, and the best way to shape it. Thanks

It will cut with speed, or power. If you have access to a wood lathe with plenty of power you will be amazed at how easily it cuts. It can also be cut on most rod lathes but you will have to use a bit more speed due to the lack of power. I have found that cutting with high speed tends to generate a bit of heat and this heat seems to soften, permanently, the Hypalon to some degree. If given the choice, I use as much power as available and cut quickly.

For cutting/shaping, I like drywall sanding screen. This is an open mesh coating with cutting grit. It won't load up quite as bad as sandpaper. I like to start with a 60 or 80 grit (this is a bit harder to find) and finish up with 120. This leaves a smooth finish on the grip but still a bit of texture which I think makes it easier to grip. Some guys will continue on down through 400 grit, but on the synthetic type grip materials I have not found this to be necessary. I think you can get the sanding screen in grits up to around 220, so you could easily go that far if you wanted.

If you are starting with a unusually large piece that needs to be worked down quite a bit, start with a Stanley SurForm flat file. This will remove material rather quickly and get you down to business.

By the way - this stuff is messy! If you can take it outside to do your sanding/cutting/shaping, so much the better. You'll also find that a bit of static electricity will be generated and make the black particules stick to everything in sight. Wear some sort of dust mask too. You can't believe how much of this stuff goes right up your nose. Don't know that it will hurt you, but it sure can't help.

Tom Kirkman
RodMaker Magazine
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Tom:
Thank you for the assistance. I will use it

I usually shape my grips by using a drill press, something with at least a 1/2 chuck. A piece of metal rod (stainless, aluminum, or steel) 3/8- 1/2'' or all-thread will do. Just make sure it is straight. Fit the grip to the rod using tape. Make sure it is a tight fit or the grip will spin.
When making longer grips support the other end of the shaft using something like a pillow block bearing or some sort of bushing to prevent excessive wobble.
Obviously this can be a hazardous way of forming grips if your not careful. Be sure to work at comfortable speeds (drill).
I like to use a surform file to get my rough dimensions. Then I use scotchbrite to progressively make the grip smooth. Usually a black for rough then a green to finish it off. I don't like my grips glass-smooth. Get your self a cheap plastic caliper to monitor your progress when shaping. I've been doing this for a while with excellent results. Besides you can complete a set of grips for a small spinner in a matter of minutes. Good luck.