The ancient martial art weapon known as the tonfa is essentially two wooden dowels connected at a right angle. As such, it is very easy to create and requires very few items.
Purchase two wooden dowels. The larger dowel that will make the shaft of the tonfa should measure from your elbow to 1 inch past your outstretched fingers. The dowel that will be the handle should measure from the bottom of your clenched fist to 1 inch past the top of your fist. Both dowels should be at least 1 inch thick.
Sand both ends of the dowel that will be the shaft of the tonfa until they are rounded.
Sand one end of the dowel that will be the handle to create a rounded end. Sand the other end into a peg shape that will fit into a hole drilled in the longer dowel.
Drill a hole in the tonfa shaft 1/3 of the way down from the end. This hole should be sized to accommodate the peg-shaped end of the tonfa handle.
Insert a small amount of glue into the hole drilled into the tonfa shaft. Also apply a small amount of glue to the peg-shaped end of the tonfa handle.
Insert the peg-shaped end of the tonfa handle into the hole drilled in the tonfa shaft. Allow glue to dry completely.
Wooden dowels can be purchased from most hardware supply stores or lumber suppliers. Make sure the drill bit used is slightly smaller than the width of the peg-shaped end of the tonfa handle so as to create a tight fit.
Always exercise caution when using power tools.