reinforce sched 40 pipe

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A 2500# log got out of control and broke my peavey (a tool used as a lever to move large logs) handle.  I have some 1 1/2" schedule 40 pipe in the shop that I will make into a replacement handle but I would like to reinforce the pipe against bending in one direction.What is the best way to reinforce the pipe without impairing my ability to handle it?  Would welding a 1"x1/8" piece of strap to the lower half of the pipe make much of a difference?http://www.traditionalwoodworker.com/images/240-2400-lg.jpgLast edited by gwiley; 10-19-2011 at 12:53 PM.Hobart LX235Victor 250 Oxy-Acetylene Rig (welding and cutting)Bobcat 773F-350, 1999, 4x4, 16' 10K# trailerOutdoor Wood Burner - 10 cords/year
Reply:Hello gwiley, I am assuming that you are avoiding using Sch. 80 pipe due to the weight issue. Barring that, you might try using a piece of 1/4" flat bar internally placed with the 1/4" thickness vertical to your load. You could then simply apply a couple of tacks at both ends to keep it in place. You might have to have this piece sheared to the proper width to get it to fit snugly and actually help with the flexing. Hope this makes sense. Good luck and best regards, Allanaevald
Reply:I would look to slip something down inside of it instead.They make 1-1/4" pipe, should be a nice snug fit.Could be a full insert or just over that area you think is most affected.Can go further and put more pipe inside the 1-1/4" to start to go toward being solid insert. Depends on your considerations, weight, etc. If I did just a partial insert you can hold it in place by drilling thru, pinning it, pein over, smooth, or weld.Could be done a number of ways but I would put it inside, make the peavey look and work as normal. You can use that pipe in pipe trick for a ton of things. Sometimes you need tubing instead of pipe to get it just right in some diameters.
Reply:What about about a piece of angle?   O>Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:How about drilling say 1/2" holes in a row up the handle maybe every 6 to 8", slip in the flat bar and weld it threw the holes and weld them closed at the same time. That has to add strength.
Reply:Originally Posted by trapperjohnHow about drilling say 1/2" holes in a row up the handle maybe every 6 to 8", slip in the flat bar and weld it threw the holes and weld them closed at the same time. That has to add strength.
Reply:Originally Posted by trapperjohnHow about drilling say 1/2" holes in a row up the handle maybe every 6 to 8", slip in the flat bar and weld it threw the holes and weld them closed at the same time. That has to add strength.
Reply:Originally Posted by ThorsHammerSeconded.The only thing I'd add is some sort of grip on the outside. Fabric tape, bat grip, tennis racket grip, foam rubber, etc. that pipe is going to be slick. Especially when your gloves/hands are wet.
Reply:I vote for the internal stiffening bar plug welded to the pipe as previously mentioned.For grip, truck bed liner with the rubber granules in it would be quick and cheap to apply.  This is the stuff in the can that you have to stir for a good five minutes before its mixed well.
Reply:I'm sure fabric tape would be cheaper, and quicker than the bed liner, though wouldn't last as long. I would only use it if I was doing something else that needs to be done with the liner.If we didn't work in the rain, nothing would happen up here.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Good idea on drilling the pipe, if ur not to picky on how it will  look, u could also weld a piece of angle across the effected area as mention.  Trying to sleeve 1 1/2" through the inside with  1 1/4" does not fit..... I've tried
Reply:why not buy a lightweight but much stronger than wood fiberglass replacement handle?  I am imagining that to become as heavy as the 5'  metal pry tool I use to break / leverage rocks out of the ground.. not sure if it is just called a pry bar or not..https://www.heimanfireequipment.com/...a09f0cc46518f0using this thing for more than an hour or so is a real workout...miller syncrowave 250hobart handler 140home made 400 amp engine driven in progress...