GreenLake wrote:I mounted my own tiller extension as far forward as shown and later regretted that choice. As mine disconnects it would have been nice to have a full grip-width of just wood in front. I also discovered that my hands will find any bur or sharp corner eventually, no matter how minor. If rounding the base isn't an option, and it may not be, because of the risk of distorting the race, then I'd look into using a bit of epoxy putty (epoxy mixed with wood flour) to provide a smooth connection to the handle.
I do think it is too far forward, but as I said I used one preexisting hole in the tiller as a guide, so only put had to put one more hole in. I think I will refinish the tiller this winter, as it is starting to grey in a few spots. I can seal the forward holes, use the rear as the new front hole, and then I think I will have a full hand's width+ in front of the joint.
I might be able to bend the base. There's no bearing, just the rivet axle and a ceramic washer for the swivel. They were cheap swivel casters. If it doesn't seem like the bend is going to work though, and I'm not sure that it will, I'll likely grind down the edges as much as I can to minimize the profile. I should hit the edges with the grinder again anyway, and then buff them out.
GreenLake wrote:I would also use clear epoxy as a base on the extension. That will seal the wood and stop it from "working". Any varnish you put on that base will no longer be stressed the same way and it will take longer to develop cracks. I use polyurethane (water based) instead of varnish on my wood trim (DS1) and the epoxy seal has made all the difference. Some pieces have now gone for 4-5 seasons without needing a touchup.
I'm afraid it's too late for the epoxy base. I have already started sealing the dowel. I am using polyurethane though (but just interior grade- it's what I had laying around). I've just put the third coat on and was planning on doing about 6, so I hope it lasts at a year or two. It is going to wear hard at the clip bracket, but I don't see how I can avoid that. It has to be tight to hold the extension in place when not in use. I can work on bending the clip into the best shape. I'll keep your epoxy advice in mind when it's time to refinish the tiller.