Aluminum & Wood Refrigerator Door Handle DIY

In one of my visits to my parents house, I noticed that the Refrigerator Door Handle was cracked and was about to break.

After a few months it did...

My dad asked me if I can glue it back.

(I was just waiting for the handle would break) I told him I was going to create a new handle.

Hope you will like this project and find it helpful, if you have any comments, Please write me.

Thank you!

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Tools:

1. Tape meter & Pencil
2. Hammer
3. Gloves
4. Protective headphones
5. Protective glasses
6. L-Square
7. Cutting disc
8. Flap disc
9. Angle Grinder
10. Caliper
11. Metal saw
12. Oil
13. Jig saw
14. Clear coat spray
15. Wood oil
16. Sanding paper
17. Orbital sander
18. Allen key
19. Screwdriver

Materials:

1. Aluminum flat bar 5x30 mm
2. Screws and nuts
3. Beech Wood

First I measured the size of the original handle and the dimensions of the screws holes and the distances between them.

I started from the top, I took aluminum bar and marked the locations of the holes and drilled the top two holes using a drill press.

I laid the aluminum segment near the original plastic handle and marked the bending area.

I closed the profile in a vise together with an iron pipe then I bent the aluminum on the pipe to get the radius of it.

then i put the two handles next to each other and marked the end of the handle, then I cut the remainder.

After I saw that the measurements and the bending angles were good, again I put the two handles Next to each other and marked the locations of the bottom screws. (If I missed out here, the screws wouldn't go into the refrigerator holes and the handle wouldn't fit.)

Important Tip:

Use oil during drilling, the oil helps reduces friction and cool the drilling area and keeps the bit in good shape, and makes the drilling an easier operation.

With an angle-grinder and flap disc, I've gently sharpened all the aluminum surface to be smooth, and rounded the corners.

I took a beech wood and marked the general measurements I valued, the goal was to get from one board 2 identical parts to cover both sides of the aluminum.

So first I had to drill 2 holes for screws and the sockets to the screw heads.

Then I split it in two using jig-saw.

It's not the best tool for this sawing type, but that's what I had at the time.

I sand the wood – to make it more subtle and comfortable to grip.

After I was satisfied with the wooden finish I put it on the aluminum in the final position, and I marked the screw locations for drilling.

I painted the aluminum on both sides with clear coat spray, for the wood I applied wood oil.

After drying I put everything together and went to my parent's house to install back the new and upgraded handle.

Luckily the screws went right into their place!

My parents were very happy and I enjoyed the whole process.

Now I have to make the upper handle in the freezer to match the new one.

:)

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