Metalworking a Replacement D-Handle

Metalworking Workshop
Metalworking a Replacement D-Handle
installed and ready to go
The D-handle installed and ready to go.

This D-handle build came about when the grandkids and I decided that we needed a wagon to haul our buckets of fishing gear and poles back to the lake instead of carrying them.

Instead of buying one we decided to make one out of material in the scrap pile. When the wagon was almost finished, I looked around for a commercially available D-handle to attach to the tongue (the piece that connects the handle to the wagon body). Not finding one, I decide that I could try making one. The handle in the pictures is the result.

The handle can be made out of any weldable pipe or, for that matter, square tube. I chose a ¾” electrical conduit, mainly because it was handy. At 16″ long, it had room for a four inch grip area in the middle and six inches per side to form the “D” part and mount section.

After you have cut your metal, you can begin bending the sides.

Finish up by bending your piece into the shape of a D-handle.

After finishing two of these handles (I didn’t take pictures of the first one) I realized there were several other possible ways this handle could be made. The more you make, the more you see how to make other things.

1 thought on “Metalworking a Replacement D-Handle

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Mancil Russell

Mancil is a lifelong resident of Independence, Oregon. Served in the Navy and is a retired telephone repairman. He is a father, grandfather, great grandfather, tinkerer, ski/snowboarder, and car guy.

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