How to Make a Bungee Cord Hook
Bungee cords make excellent tie down straps for almost anything. But occasionally the end hooks are broken or lost. You can purchase replacement hooks at most hardware stores, but if you're the handyman type, you can also make bungee cord hooks yourself.
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Instructions
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Rubber Cords
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Buy a length of 1/8-inch steel rod. Don't be tempted to buy aluminum because it's less expensive and easier to work with. Aluminum is a weaker metal and not strong enough to withstand prolonged use on a tie down cord.
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Clamp 1 inch of an end into a table vise, standing straight up. Lay a hammer handle (or similar sized, rounded object) across the top of the vice; parallel to the jaws. Hold it in place with your left hand.
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Grab the rod approximately 12 inches up from the vise, and carefully bend it toward you with your right hand. Bend it across the handle until the remaining rod points nearly to the floor, forming a curve.
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4
Remove the rod from the clamp. Reposition it to hold the entire curve in the clamp's jaws. Reposition the hammer handle beside the rod, perpendicular to the jaws. Be certain you have the hammer on the correct side to form an "S" rather than a "C" once the rod is bent.
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5
Bend the rod across the handle. Reposition the newly formed hook so the excess rod is easily accessible. Use bolt cutters or a torch to remove the excess. If desired, run the ends of the bungee cord hook across a grinder to smooth the tips.
Elastic Cords
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Purchase a length of 1/8-inch aluminum rod. You will not be able to bend steel rod into the appropriate shape for this type of bungee cord without specialized shop equipment. As a result, it won't be as strong as a rubber strap with steel ends. If strength is crucial, consider switching to a stronger type of bungee strap.
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Place the rod 4 inches into the vise, pointing out the side of the clamp. Insert the shaft of a narrow, but long screwdriver into the clamp next to the rod. Only the handle of the screwdriver should protrude from the clamp.
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Wrap the rod around the screwdriver handle four times, forming a spring.
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9
Remove the screwdriver from the clamp, and tighten the rod back in place. Remove the excess rod with bolt cutters at the base of the spring.
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Holding the spring in your hand, use the pliers to curve the end of the rod into a hook. Pull the last coil of the spring slightly up inside itself to avoid a sharp bottom edge. To attach to an elastic bungee cord, push the end of the cord into the spring. Insert the spring into the vice and tighten.
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Tips & Warnings
Heating the rod with a torch can make it easier to bend.
Purchase replacement hooks and keep them on hand. The next time you need one, it will be readily available and exactly the correct size.
