Wow - thanks for all the comments, offers of possible handles, and ideas.
In going with X1 Mike's "just make something" theme, I looked at a few make it yourself options.
Tool related handles -
- Crow bars, pry handles, axes , ice saws, pipe wrenches, alligator wrenches and bench vise handle (with two screw ends as the spacers) were all contemplated. The first ones were either too big or posed safety hazards for walls and coworkers. The bench vise handle seemed interesting but most folks would not get it.
- I did have a couple of orphan Craftsman raised panel double box end wrenches (1-1/16", 1-1/4" & 1-1/8", 1-5/16") as shown in the first and second photos. They look to be unused. The shallow offset makes using a wrench like this an option. But do you get turned in to the "Irony Police" for using a Craftsman wrench handle on your Snap-on tool box?
Still an interesting option.
Non-tool related:
- For the industrial theme, ground shafting possibly combined with Thomson Rail pillow blocks were examined (third photo). But the ground shafts looked too much like other handles and the pillow blocks had too sharp of edges (would look neat though).
- 1-1/4" threaded rod (photo 4) looks nice, but the sharp edges were a problem. I did find the matching tap however
A more natural handle:
- For a more subtle effect, I did run into wood the could be interesting (top of photo 5). The slab of what looks to be teak wood could me finished quite nice, but it is a little thin (3/4") so I would probably mill a hidden slot for a metal plate to anchor the standoffs.
- On the oppose end of the wood spectrum is a leftover piece of a old hardwood maple butcher block bench top (1.1" x 1.8") - see bottom of 5th photo. I picked up a couple large used table tops years ago. One was good and the other was exposed to the elements and the old wood glue was coming unstuck. I re-purposed the less desirable one for so many nice machine bases and other projects where "over-kill" is not just a word but a theme. This is somewhat the "easy" solution in that while routing, sanding and sealing is required, it is really hard wood so there is no structural or reinforcement concerns. I'll probably skip staining as this wood is so dense it really does not stain effectively. I also found some nice stainless steel standoffs that would just need to be parted in half to use (photo 6).
From a cool factor, the wrench probably wins.
From a usability perspective, hard maple can be formed into something much easier on the hands.
I am leaning slightly more towards cool, but usability may win out.
Thanks again!
