That said I'm now going to show you guys how I replaced the broken handle of our cast-iron pan. It broke about 2 months ago and my dad just put a screw and bolt on it to keep it useable. I thought it would just be a temporary fix but it just stayed on the lid - and nobody seemed to care. So I finally had a reason to order some Sugru ;)
Step 1: The Parts You Need
a plastic cork
one minipack of Sugru
some masking tape (not pictured)
a lid with broken handle
some soapy water (if required)
cordless power drill
allen key or screwdriver, depending on the bolt you use
Step 2: Drilling the Cork
After that came the fist fitting test. I put the screw through the hole in the lid and just stuck the cork on top. The bolt I used was a bit too long, so I just shortened it a bit with my dremel in the next step.
Step 3: Securing the Cork
Step 4: Sugru!
I didn't know how the Sugru would react to the cast-iron and I didn't want to know either. So I decided to put some masking tape around the cork.
After that comes the fun part ;)
If you follow the instructions on the Sugru packet it is quite easy to work with. I just found it a bit difficult to get a nice and smooth surface but maybe that was just because I had relatively little material to work with. If you want to do this fix I would recommend to either shorten the cork or to use two minipacks.
Step 5: Molding the Sugru
Take your time and mold the Sugru nicely around the cork, because the mistakes you make while molding will stay forever ;)
Step 6: Finishing
When you're happy with the texture just let it sit for 24 hours. The Sugru will cure and be as resistant as it should be. After the Sugru is cured you can remove the masking tape and use your new handle ;)
Step 7: Conclusion
So now I'm heading back to the drafting table and start from scratch, but I'm going to post my new 'ible if it works, promise!