Aluminum & Wood Refrigerator Door Handle DIY : 13 Steps (with Pictures)

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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Supplies

Tools:

Tape meter & Pencil
Hammer
Gloves
Protective headphones
Protective glasses
L-Square
Cutting disc
Flap disc
Angle Grinder
Caliper
Metal saw
Oil
Jig saw
Clear coat spray
Wood oil
Sanding paper
Orbital sander
Allen key
Screwdriver

Materials:

Aluminum flat bar 5x30 mm
Screws and nuts
Beech Wood

Step 1: Taking Measurements

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

Step 2: Drilling Top Holes in Aluminum

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.

Step 3: Bending the Aluminum

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.

Step 4: Drilling Lower Holes in Aluminum

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.

Step 5: Refine Aluminum

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

Step 6: Wooden Handle Cover

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.