Introduction: ScrapHeap Beer Faucet Handle - Copper Style

About: A guy that needs to build stuff.

Here is a quick build to make some cool looking taps for not a lot of money or effort.

These are based on 3/4" Copper tubing, your standard Home Depot stuff.

I also added a different version earlier, if you like the steel version:

I found this tubing UNDER my Workshop. Who knows how long it had been there!

I made 3 of these and settled on using the copper version on my Keg-orator


A mallet, tubing cuter, access to a 3-D Pritner, a 3/8-16 tap and a tap measure

Step 1: Print Your Files

These are quick and easy

55% infill

.4 Nozzle

.2 layer

Watch over extrusion on part Copper Bottom. You will have to work harder chasing threads.

A note about design. I am lazy. In order to make the threads in the Part "Bottom", I could have 3-D modeled it. But that requires work. If you go to Grab CAD or SolidWorks or McMaster Carr, you can find pretty much every piece of hardware known to man. I found a 3/8-16 nut, downloaded the model and assembled it to the "Bottom" in FreeCAD. After that, you can simply select both parts and export them to an STL file. Boom. Threaded hole you can print.

Step 2: Cut Your Copper Tubing

Measure to 8"

Align the cutting wheel with your mark.

Tighten the bottom jaw with a fair amount of force.

Here is a tip I learned form an old timer that pretty much taught me everything I know. Tighten the cutter and make one revolution. Only one. Then tighten. Repeat. It should take no more than 4 revolutions to cut a piece of 3/4" Copper Tubing. I remember getting fussed at, asking me if I was going to retire cutting a piece of Copper Tubing.

Step 3: Deburr the Inside of Your Copper Tubing

Use the tool on the cutter to remove 80% of the burr. You will need to use emery cloth or sand paper to completely remove the burr from the inside of the tubing. The assembly of this handle relies on the Inner Diameter of the tubing. Too much burr and you will not be able to assemble the handle.

I used this to polish the copper tubing. -

It adds a nice grain and removes imperfections.

Step 4: Gather Your Parts

Notes are in the pictures

Step 5: Chase the Threads in the Part "Bottom"

As cool as it is to print threads, I cannot get by without chasing the threads.

As long as you are not over extruding while printing, you can thread a sharp tap through the hole. The set I have was purchased at Harbor Freight just for projects in plastic. Costs $16.99 full price, but never buy without the 20% off coupon.

Step 6: Snug a "Top" and a "Bottom on Either End of the Copper Tube

Step 7: Use a Mallet to Hammer It All Together

Step 8: Add the Tag. Pictures Explain the Process.

Step 9: Here Is the Before and After

Snap the tags via the ball chain and screw on your new tap handles.

The process, in case you don't know, is to run the lock nut on the faucet all the way down. Then thread the handle all the way down. Back the handle off until the orientation is where you want it. Run the lock nut up to lock it all together.

There you have it. You are ready to pour a cold home brew form your keg-orator. Invite some friends!!

I was thinking of putting these on Etsy, thoughts?

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