How to Make a Pain Stick

Instructions by Kirr (on Fetlife) and Kristen

Pain sticks (also known as “evil sticks”) are good for creating sharp pain very quickly: hold the handle, pull back the end of the rod and let go, and it will snap against the skin. This is a great project for people who may not have a lot of maker/hacker/crafter experience (like me) — it doesn’t require many tools, and the materials are relatively inexpensive. It’s also fun to do with friends since one 48” carbon fiber rod will make about four pain sticks.

Thanks to Kirr for showing me how to make the pain stick and helping me document the process!

Update, 6/26/12: It turns out that the end of the pain stick can tend to split after repeated use. In order to prevent this, dip the end in a little two-part epoxy (look for double-barrel syringes of it in your local hardware store).

How to Make a Pain Stick

Print recipe

Pain sticks (also known as “evil sticks”) are good for creating sharp pain very quickly.

Materials and Tools

1 1/16” diameter carbon fiber rod (i.e., http://www.mcmaster.com/#2153t66/)
Two-part clear epoxy (hardware stores carry this, look for a double-barrel syringe)
Wire (or lanyard lacing, string, or twine)
Plastic tool dip (hardware stores carry this)
Ruler
Pliers (if using wire)
A multi-tool or wire cutter

Directions

Step 1.
Using the ruler and the multi-tool, cut off a piece of the carbon fiber rod that’s about 10” long (precision really isn’t important).
Step 2.
To make the handle, bend one end of the wire around one end of the carbon fiber rod. Use the pliers to crimp the end so it stays in place. Coil the wire around the rod about five times.
Step 3.
Cut the wire, and use the pliers to crimp the other end of the wire so that it’s snug against the rod. If you’re using lacing or string, you’ll need to tie one end around the rod, knot it, wrap it around the rod about five times, and then tie it off with another knot. Trim the excess string.
Step 4.
To finish the pain stick, follow the instructions on the tool dip to coat the handle with plastic. Slowly insert the handle into the tool dip, covering the wire or string with a coat of plastic. You may need to use multiple coats depending on how thick your tool dip is.
Step 5.
Set the pain stick up to dry, handle-side-up. Check the instructions on the tool dip for recommended drying times.
Step 6.
Mix up a small amount of the epoxy according to the package instructions. Dip 1/4" to 1/2" of the end of the carbon fiber rod in the epoxy. Roll back and forth on a piece of cardboard or scrap paper to remove excess epoxy. Let dry (check the package for drying times). The epoxy will keep the ends of the rod from splitting after repeated use.