Garden Trowel

My wife needed a new garden trowel. I wanted to see how well I could make one from scrap materials I have on hand.

Materials

1. 20 gauge sheet steel.
2. 1 inch thinwall metal tubing
3. 1/8 inch rod

Tools

1. MIG welder
2. Power bandsaw for cutting metal
3. 4 inch angle grinder
4. Spring clamp
5. Hammer
6. Vise
7. Measuring rule
8. Square
9. File
10. Bending form tool

My son-in-law had some pieces of formed 20 gauge sheet steel that were being scrapped. I marked one for a piece 4 x 6 3/4 inches and cut it. I had planned to use a cutting wheel on a 4 inch angle grinder, but the cutting was too slow, so I used a portable bandsaw mounted as a bench top bandsaw.

I used a piece of pipe about three inches in diameter to curve the sheet steel. I made a centerline on the sheet steel to help align it with the axis of the pipe. I secured both in a vise. I used a 16 ounce hammer to gradually form the sheet steel to the contour of the pipe. The curve in the sheet steel was a little tighter than I wanted, so I placed the formed piece in a vise and gently squeezed it to open the radius of the curve. This meant moving the sheet steel in the vise several times to keep the curve in the sheet steel even.

I want a curved front for the trowel with a slight point at its tip. I drew the curves by hand while paying attention to the centerline.

The sheet steel I have has a coating of paint I need to remove at weld points so I can weld pieces together.

Cut a piece of thinwall tubing about 6 1/2 inches long for the handle. The second photo shows the diagonal slice I removed from one end of the tube. My angle was more shallow than I intended and the result was an open half oval that extends beyond the back end of the curved sheet steel trowel blade. (This will need to be closed in a later step.)

The diagonal cut in the tube allows fitting the handle to the trowel blade. Do your best to make the handle straight with a line down the center of the trowel blade. I used my thumb to hold it in place until I could position a spring clamp. The ground clamp from my welder is attached to a handle on the spring clamp. Tack weld the handle to the trowel blade in one spot. Twist the handle side-to-side a little, if needed for alignment, while the weld is still hot. Weld around the area where the handle joins the trowel blade. I set my welder voltage and wire speed for the recommended numbers for 20 gauge steel. I got good penetration, but I welded in spurts to avoid too much heat on thin material and burning holes. The welds are not beautiful, but they are strong.

Make a kerf in the front of the handle with a cutting wheel on an angle grinder. Pound the end of the handle down with a hammer and weld the kerf closed. The purpose is to keep soil from going up into the handle. In the photo one can see where metal came to be too hot and I blew a hole in the front end of the handle. I closed that hole, too.

I opened a kerf on the half oval so I can bend the handle to make it nearer to parallel to the length of the trowel blade. Use a file to remove the coating on the tubing for a better welding experience. Bend the handle to close the kerf and weld the kerf closed. Grind to smooth the weld bead.

I pressed a piece of paper over the half oval opening to impress a pattern into it. I trimmed the paper pattern and used it to mark and cut a small piece of 20 gauge steel. I welded it over the opening to cover the opening.

I bent some 1/8 inch rod to make a loop for hanging the trowel on a hook. The bending tool is one I made. Weld the loop where it fits inside the handle end. Secure the loop so pressure from the welding wire does not push it out of place as you begin to weld.

Smooth any sharp or rough edges.

This trowel took some time to make. Trowels can be purchased for relatively little. You will need to decide if making one is a good investment of your time. This trowel is sturdy and maybe a little heavier some, but should last a very long time.