Pictured is a handle grip I welded from scraps when the plastic grip on our snow shovel cracked and fell off of the wooden portion of the handle. This Instructable will detail the process of making a new handle grip. A welder is required.
Step 1: Bend the Flat Part of the Handle Grip
The piece inside the yellow lines is 3/4 wide and 1/8 inch or slightly more in thickness. It is 11 inches long. The size of your hand will be a factor, but I bent this one 3 inches from each end, leaving 5 inches across for the width of my hand.
Step 2: Add the Round Portion of the Grip
The round portion of the grip is 3/4 inch black pipe. Cut it 5 inches in length. Weld it between the ends of the flat you just bent. Grind the welds smooth so rough spots do not snag on your gloves or scratch your bare hands.
Step 3: Front Attachment
Get a piece of flat steel 3/4 inch wide and 3 inches long. It should be about 3/16 inch thick. Drill a 1/4 inch hole for the screw that will go through the handle. Drill a countersink if you will be using a flat head screw.
Weld this piece to the upper part of the handle grip you just finished (top of the yellow outline).
Hold this assembly on the wooden handle and begin drilling a 1/4 inch hole through it.
Step 4: Make the Rear Attachment
Cut a piece of 1 inch angle iron 3 inches long. Hold it on the shovel handle in its position and use the drill to score some marks on it indicating the center of the hole. Drill the hole in the angle iron.
Put the screw through from the front. Attach a nut. Tack weld the nut in place. Tighten the screw.
Weld the corners of the angle iron to the flat portion of the handle grip. There is not a lot to reach with the welder, but this adds a lot of strength and stability to the handle grip.
Grind any rough edges that could snag gloves or scratch skin.
Your shovel now has a handle grip that will last much longer than the original plastic grip.