Lifetime Handles

The fiberglass handles on our Corona compound action loppers eventually weaken and break. In the past we had no way to repair them so the cutting jaws were thrown out and the handles were recycled as stakes to mark plantings.

Now we are experimenting with using aluminum pipe to replace the handles. The first step in the modification is to drill out or grind off the end of the rivet which holds the original handles on, then use a long punch to punch it out. The smaller pipe fits over the cutting jaw extension but since the pipe is hollow and cylindrical and the extension is flat, it does not fit tightly. This is resolved by shaping some half round wood molding to fit in the pipe on either side of the extension. Lacking precise forming equipment, the wood will either be slightly large, in which case it can be hammered in, or a little loose, in which case it can be dipped in water, then coated with Gorilla Glue just before insertion. Gorilla glue expands and dries to a dense foam which will fill the gaps and hold it in place. 6mm holes are drilled in the wood after it is inserted and bolts are then used to replace the rivets which formerly held the handles on.

The larger pipe fits over the black end of the handle. The OD of the handle is 1.50 inches and the ID of the pipe is 1.49 inches so some material on the end of the handle has to be ground off. It is a hard rubbery material. I used a drill press with a cylindrical, flat end 6mm diameter silicon carbide bur from McMaster-Carr. Drilling holes in the pipe exactly opposite each other and at exactly the right distance from the end to line up with the holes in the handle was beyond my technology. The bur was used to adjust the pipe holes in the proper direction for the bolt to work. The big pipe seems to be tight but if it later loosens up we will use Gorilla Glue for it also. Red electrical tape is wrapped around the handle to make it more visible and artistic.

The first modified lopper has one big pipe and one small pipe. The smaller pipe is lighter and cheaper but not as strong. If it turns out to be strong enough it will be used for future repairs. If it breaks we will use the larger pipe. Heavy duty fiberglass reinforced plastic pipe was investigated but it was heavier and more expensive than the large aluminum pipe.

The pipes were ordered from OnlineMetals.com, the same place we get the aluminum angle for upgrading the cutters. They have pipes of different diameters, wall thicknesses, and materials and they give the detailed dimensions. If you want a high tech lopper and need to get rid of a lot of money, you could order brass, stainless steel or titanium pipes.