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Old 11-29-2021, 02:12 PM
Aaron_W Aaron_W is offline
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Default Simple metal handle, how to do the center?

I'm looking to make a few handles like this




I've got a bender to make the basic handle shape, but that curved center has me flummoxed. Thinking bend the handle shape first and then? English wheel, wack at it with ball peen hammer, press it in an arbor with a piece of round bar ?

Very new at this, and yes I know I can buy these for like $3 but where is the fun in that.
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Old 11-29-2021, 03:25 PM
Gareth Davies Gareth Davies is offline
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I’d press it with one piece of round bar between 2 others tack welded together, with a spacer if required. Yes, press the top hat shape first.
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Old 11-29-2021, 04:20 PM
crystallographic crystallographic is offline
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I can think of a number of ways .... all fun.
But a different approach: after the hat section is formed, flip over onto hard round bar fixed in sturdy vise and hammer the two edges over, allowing the stretched edge to drop - the ends will be most hammered, tapering to middle "zero area" which becomes a simple radius bend.
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Old 11-30-2021, 10:23 PM
fciron fciron is offline
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I don't think there's any actual stretching in those. If you bent the lengthwise curve first, then the offsets will flatten when you make the right angle bends.

I'd probably put the U in by pressing some round bar into a v-block.


But why not make a more interesting handle?
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Old 12-02-2021, 09:17 PM
Aaron_W Aaron_W is offline
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Thanks, this gives me a couple of options.

As far as why not something more interesting, I'm building a workbench for an old lathe and this simple handle style just seems appropriate for something utilitarian from the 1930s. They will be painted, another reason not to just buy as I don't want a galvanized finish.


I am comfortable working with wood, have been doing some machining and welding for the past couple of years, and am just now getting my feet wet with metal shaping. These handles seem like a nice crawl before you walk project.
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