Summary

If you're looking for an over done replacement handle for your 5 gallon bucket, look no further! I needed a handle that wasn't just a press fit as I have not had great luck with them staying in place. With all of the time on my hands during the 2020 pandemic, I went to work designing a 90mm long split handle with threaded ends. The split section will accommodate a few different styles of wire with a Ø10mm through hole. The 5mm wide slot on the caps allows for installation on the existing wire. Cap threads are 2 lead, half turn. Each cap also has a hole that aligns with one in the split body for a M3 locking screw (up to 20mm long) to insure the caps will not come undone during use. I also added holes in the split that can be used for alignment pins. They are sized for raw filament to be used as pins. I did not use these and have not had any issues. The handle seems to be plenty strong for the job....so far!

I have included all of the stl files for each part. You need to print 1 of each part. The caps are NOT interchangeable. The thread on each end is opposite hand. I have also provided a 3mf file of all parts grouped together for easier printing.

Print Settings

Printer:

Flash Forge Creator Pro

                                            Rafts:                      
Doesn't Matter

Supports:

                                            Resolution:                      
.15

Infill:

40%

                Filament:                                     Hatchbox PLA                                    Red                    
                        Notes:                     
These settings are just what worked for me and are not the only way. There is a fair clearance, but reducing resolution could make the threads tight in the orientation in the 3mf file.

5gallonbucket

buckethandle

handle