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207401 Posts in 14860 Topics by 6669 Members Latest Member: - c0urtn3y14 Most online today: 21 - most online ever: 247 (March 27, 2011, 07:39:10 AM)
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Author Topic: D.I.Y Aluminium Nunchaku with Chain  (Read 5691 times)

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Austria Austria

Posts: 31

« on: April 22, 2009, 01:46:52 PM »

First I want to say hello to the community it is really great here  respect. This is my first post, and I hope
it will be useful. Btw If anyone finds grammatical mistakes in the following tutorial... I didn't have much time for this, because
I'm kinda busy right now, and in the next few weeks. So please keep the mistakes  smilez

Aluminium Nunchaku D.I.Y


The Parts

Well, this is the list of the parts I used, because I think these work best for me, you can choose whatever you like. Next time I will try to use a 23.5 mm aluminium pipe and make it 28cm long with a 19cm chain, but I want to get some rings, like the chinese Bruce Lee Nunchaku V has. Does anyone have an idea about the ring part, where I can get them, because it is not that easy to find metal rings which are completely round…
Ok but first the important things.. Here’s the list
1 inch = 2.54 centimeters smiley

1x Chain  whahaa
1x 19.5mm aluminium pipe
4x19.5mm plugs for furniture (i hope you know what I mean, because I dont know exactly how they are called in english)
4x M4 nut (M4=4 millimeters)
4x M4 countersunk screw
4x M4 sleeve nut

Cut the aluminum pipe into two pieces with 32cm each.

You can insert the first two plugs in the bottom of the two sticks.

Next drill two holes in the plugs. It is for putting the chain trough later

Next drill the holes in the two aluminium sticks, each one 2cm away from the top.  I used a 4.5mm drill bit because the sleeve nuts and the countersunk screws are both M4.
Next use a tool to rasp a dent in both sides of the holes. The dent for the countersunk screw must be deeper than the dent for the sleeve nut. You will also have to file the hole for the sleeve nut slightly larger otherwise it won’t fit through.

Now comes the shitty part. Putting the chain through, which is obviously too thick for the plug!

Squeeze the second chain link a little, so that the plug could remain round when you have put the chain completely through.

When you are done it should look like this.

I made it outside for demonstration only, but this is how it should be on the inside of the nunchaku.
I used the nuts left and right for changing the balance point of the nunchaku a little. Because I think it will have more momentum, if it is slightly heavier on the top.
Now put the two plugs in, but this could be a little tricky, you will probably have to use a tongs, otherwise it will take you more than a couple of minutes.
Finally it should look like this

Last but not least the credits for this tutorial.
Many thanks to irvmstr for his helpful ideas and advices, and I also want to thank Michael from for the idea of fixing the chain with the sleeve nuts.

Oh yes, and if you have any ideas for improvement or where I can get some metal rings for my next nunchaku, as mentioned above, let me know!
 2 thumbs up

Before I forgot the length of the chain is 12cm and the weight of the nunchaku is 190g rolleyes


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Mexico Mexico

Posts: 2290

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« Reply #1 on: April 22, 2009, 01:53:16 PM »

Great tutorial!! welcome to the forum + k!!
thanks for sharing!

The Mexican Elf!
Sin Sexo ni Cerveza, Oz pierde la Cabeza.

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United States United States

Posts: 998

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« Reply #2 on: April 22, 2009, 03:17:15 PM »

Wow, that is a really well thought out tutorial. I like it laid out like that much better than a video... +Karma
 2 thumbs up respect 2 thumbs up

Global Moderator

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Indonesia Indonesia

Posts: 1703

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« Reply #3 on: April 23, 2009, 07:07:54 AM »

Cool nunchaku! 2 thumbs up  But it's difficult to find those plugs here in my town, though.
Global Moderator

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Romania Romania

Posts: 2761 Choggsy
« Reply #4 on: April 23, 2009, 08:28:11 AM »

great DIY man! Have some karma!  Clap
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