September 21, 2023
Description
On my sister's birthday she had a few friends and myself up at Lake Tahoe, and within two seconds of being handed her paddle at the beach, I dropped it in the parking lot and the handle shattered.
First I looked up replacement handles, and despite this handle model being very common across various paddles you can find on Amazon, I could not find the handle itself available for sale - additionally, she got her paddle in a package deal with a board, so to get an identical one I'd have to repurchase the package for >$100, or buy a whole new paddle for $30-$40. I hopped into Fusion 360 and whipped up a replacement handle that could be easily printed on my Ender 3 v2 in PETG.
I printed it in PETG with supports, flat side down. Four (4) perimeters at 50% infill. The handle has been well-received and has so far held up better than the original handle. Being made of PETG it bounces when it hits asphalt/concrete instead of shatters.
Some things to take into account - the way the handle was fixed into the shaft created challenges in preparing it to receive the new handle. I had to use a spade bit to drill out the old plastic shaft as it was heat-welded or epoxied in with the metal shaft being compressed around it. Drilling it out left a very thin plastic layer which worked out as I used a plastic to anything (plastic or metal) adhesive to permanently attach the new handle.
I uploaded the original handle I made for my sister along with a version that doesn't have her name on it.
License:
Creative Commons — Attribution — Noncommercial — Share Alike
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