Dale Bonertz
Do they have to be pretty or just usable? I make the usable version (not much to look at). If you purchase un-seamed dimensional pipe steel (expensive) you can slide a 3/4" pipe into a 1" and so on to get down to the size gouge you want to insert. I just use the seamed variety (fairly cheap) and use whatever I need to insert into the pipe to get it to the size needed. That may be a piece of conduit or the next size down seamed pipe (lightly ground to fit) or etc. Start by cutting the 1" pipe to the length you want for the handle. Lightly grind the edges so they are not sharp. Then cut a 2 to 3 inch piece of whatever you are going to use for a reducer to get to your gouge size. Insert that into the pipe end (it should fit snug whatever you use). Drill two holes, one about 1/2" from the end and the other about 1 3/4" from the end. Tap them to accommodate the set screws you are going to use to hold the gouge. Make sure your screws go through the insert you used. Then slide a braided plastic/rubber pipe over the steel only up to where the sets screws are so you have access to them (using liquid soap helps with this operation). If you have a 3/4" gouge and need the inside of the 1" pipe to accommodate it then put a short sleeve on the outside of the 1" pipe (I used the next size up pipe for this on my two 3/4" gouges and ground the edges so they were not sharp).

Just a side note. I checked the weight online of seamed steel versus solid aluminum which most aluminum handles seem to be made of. Seamed steel is actually lighter than the aluminum per unit measure. Steel handles work great for most applications but I find that for the finesse or fine cuts that wood handles give me a better feel on the cut (most of my gouges have steel handles though). Final note is you can make many handles for what one costs from handle vendors. The process is fun - enjoy your new handles.