5 Gallon Bucket Handle Grip - Metric and SAE Versions

This handle will replace the small and often broken handles that come on 5 gallon buckets. This is designed around a standard 10 gauge wire (0.135" diameter) 5 gallon bucket handle. Often the wire handles will have a bend at the top where the handle mounts that may have to be straightened to get the handle installed successfully.  There are two models, one with a loose handle and one with a tight handle.  The loose handle has a 0.250" bore, which allows the handle grip to rotate.  The tight version of the model has a 0.150" bore which typically requires the fasteners to draw the two halves together due to the bend in the wire handle.  Once installed this one can be rotated, but typically holds position.

Both models are held together with 4 nuts and 4 bolts.  The hardware is sized for M3x0.5 x 12 mm bolts approximately and square nuts on the metric version.  For the SAE version, the hardware needed are 4-40 bolts approximately ½" long or shorter and 4-40 hex nuts which are much more available in the USA than square nuts.   The counter bores are modeled for a socket head cap screw to sit flush with the surface.

I printed these models in PETG, with 3 perimeters and 4 top and bottom layers. The printer was setup with a 0.4mm nozzle with 0.20mm layer heights.  There are few small details and it could easily be printed with a larger .6mm nozzle, with a reduced surface smoothness.   Both models are set up to be printed with the large mating surfaces flat on the bed.  The square nut slots are modeled to where there are no supports needed.