Abstract: A composite pry bar and striking tool having an elongated solid body core surrounded by a molded polymer sleeve. The ends of the tool may include varying combinations of working tips including a pointed tool, a curved chisel, a tapping cap, and/or a molded polymer cap. The working tips are preferably adhesively bonded to the ends of the tool. The molded polymer sleeve includes first and second molded grips and may be segmented to allow for shorter or longer body lengths. The solid body core is formed by a pultrusion fiber resin curing process.

Abstract: A composite pry bar and striking tool having an elongated solid body core surrounded by a molded polymer sleeve. The ends of the tool may include varying combinations of working tips including a pointed tool, a curved chisel, a tapping cap, and/or a molded polymer cap. The working tips are preferably adhesively bonded to the ends of the tool. The molded polymer sleeve includes first and second molded grips and may be segmented to allow for shorter or longer body lengths. The solid body core is formed by a pultrusion fiber resin curing process.

Abstract: A process for assembling a hand tool includes the steps of heating an elongated tang element fixed relative to the tool head, aligning a front end of a composite tool handle with a rearwardly extending portion of the tang element, and driving the heated tang element into the tool handle. The tool handle includes a thermoplastic section in proximity to the front end thereof, having an elongate tang receiving channel. The heated tang element is driven into the tang receiving channel such that as the tang element engages the tool handle, the thermoplastic section surrounding the tang receiving channel is softened and flows into intimate contact around the tang element and then hardens as the heat of the tang element is dissipated to hold the tang element in place. In one preferred form, the tang element forms a portion of the tool head which is heated and then positioned in a stationary jig.

Abstract: An adapter for connecting a tool head to a fiberglass tool handle or shaft. The adapter includes a cap having greater compressive strength than the handle. The cap fits over the end of the handle to prevent damage during assembly, use or storage of the tool. A pair of adapter sections fit around the cap and the adjacent end of the handle. The adapter sections have recesses which receive the ends of the cap. A pair of pins carried by the adapter sections extend into openings in the handle. The cap also acts as a guide to provide proper alignment of the adapter sections and tool head with respect to the handle.

Abstract: A combined insert and end plug for aligning fiberglass tool handles for attachment to tool heads and for concealing the ends of the handles. The resilient molded plastic insert has a center portion and a plurality of integral outwardly directed legs. The insert is mounted within a tool head opening so that the legs are disposed between the handle and the walls of the opening. The insert holds the handle in proper position for attachment to the tool head. The insert has a plurality of outwardly directed resilient membranes which flex inwardly during insertion and then flex outwardly by their own resilience to combine with the center portion to form a cover for the outer end of the opening.

Abstract: An assembly tool for use in attaching fiberglass handles to tools and the like. A tape applicator is mounted for reciprocal vertical movement by a double-acting hydraulic cylinder. A tool head is mounted beneath the applicator with masking tape overlying one end of the tool head opening. The applicator comprises a hollowed resilient pad which draws the masking tape tightly across the top of the opening and then presses it into sealing engagement with the entire periphery of the opening. The opening is thereby sealed against leakage of potting compound inserted into the opening to bond a handle to the tool head.