Golf club repair, once the sole domain of highly skilled clubmakers, has become a bit of a cottage industry to many golfers with the advent of easily found parts, tools and supplies. While some skills--like replacing the whipping on a classic persimmon driver--remain a highly trained and experienced skill, projects like re-shafting an iron or metal wood with a bent shaft are fairly simple projects that can be handled by reasonably handy people. Replacing your club's shaft is slightly more challenging, but still possible with the correct tools and supplies.
Difficulty: Moderately Challenging
Clamp the club with the damaged shaft into your vise so it is held down solidly.
Apply heat to the hosel of the club with your propane torch or heat gun. Continually twist the club head until the heat reaches the correct temperature to break the epoxy bond between the club head and shaft. Remove the heat as soon as the club starts to loosen so you don't damage the club or shaft.
Remove any excess epoxy inside the hosel of the club with a cotton swab, rag or dowel.
Prep the new shaft tip. Make sure the tip of the new shaft fits into your club head solidly. Use the rasp or metal file to rough up the tip of the shaft. This will make the epoxy adhere better to both the shaft and the club head.
Prepare the epoxy. Golf club epoxy comes in two parts (one clear, one colored). Mix the epoxy according the the directions on each bottle, making sure the final mixture has blended into a new color.
Seat the shaft. Slide the new ferrule onto the new shaft and apply the epoxy you mixed onto the shaft tip and inside the hosel of the club head. Then slide the shaft tip into the hosel and make sure it is seated solidly. Once the shaft is seated properly, slide the ferrule down to meet the top of the hosel and wipe off any excess epoxy.
Let the epoxy set. Epoxy can take 24 hours of more to cure properly. Set your club somewhere dry and safe, where it won't be knocked over, until the epoxy dries.
Put on a new grip. Once you fit your repaired club with a new grip and the grip tape has dried thoroughly, your "new" club should be ready for action.
Tips & Warnings
Make sure your "new" club is cut to the correct length before applying a new grip. Some shafts come in longer lengths than you need.
Make sure you use a rag or heat-resistant gloves when handling metal club heads that have been heated with a torch or heat gun.