Mini Reel Repair

07-Sep-09

Handle 2Handle 1 This article shows how I replace the handle on a Mini Reel [for polywire fencing] when it breaks. The tools I used are a hacksaw, a small lathe, a drill press and a small MIG welder. Drill bit sizes I used are 3/16", 1/4", 3/8" and 1/2". ?>

  1. I make the handle from a 1" x 9-1/2" x 1/4" flat stock [I used an arm from an old garage door opener]. Make a 90° angle 3" in from the end.
  2. I cut 2-pieces of 1/2" pipe 1-1/2" long, I squared up the ends in the lathe. I also turned the outside diameter down to 0.815" to fit very snugly inside a piece of 3/4" PVC pipe.
  3. The fence hook can either be cut off the broken handle or made from a 3/4" x 2" x 1/8" flat stock. If made from flat stock, bend it in the middle at a 60° acute angle.
  4. The locking pin holder was made from a 1/2" hex bar I had laying around. I cut a piece 1-1/4" long and turned the ends square with a final length of 1-1/8". I drilled a 1/4" hole all the way through on the lathe and then drilled it out to 3/8" x 3/4" deep. I turned one end down to 1/2" round x 3/8" long to fit in the handle [turn it .002" over 1/2" and it can be press fit in the handle]. On the other end I cut a 60° angle. The locking pin I salvaged from the broken handle, several of the pins fit perfectly and several I had to file the 1/4" and 3/8" diameters down.
  5. The new hand hold is a piece of 3/4" PVC 6-1/4" long. I cut a notch in one end so it will slip on the handle a little further.
  6. The reel holder is made from a 3/4" x 4-3/8" turned down so it slides inside a 1" PVC. Coat it with PVC cement and slide it inside a 1" x 4-3/8" PVC pipe. If you don?t get it seated all the way immediately, cut the protruding end off, reglue it and push it in the other side. Put it in the lathe and turn the entire length except for 0.1", down to 1-1/4". Turn the end down to 1.22" x 5/8" long. Turn the same end down to 1.1" x 3/8" long. Drill a 3/16" hole crossways thru the smallest end 9/32" from the end [the edge of the hole should be right up against the 1st shoulder].
  7. Weld or braze 1-piece of 1/2" pipe on the long end of the flat bar, the same direction as the bent end. Weld or braze the 2nd piece of 1/2" pipe on the short end of the flat bar, make sure it?s on the correct edge, otherwise it will be a left handed handle. Weld or braze the fence hook in the middle of the opposite edge.
  8. Paint the metal handle, but not the fence hook where the polywire wraps around.
  9. Drill a 1/2" hole 2" from the edge of the 1st piece of 1/2" pipe. Insert it in the handle and tack weld it if necessary. Grease the locking pin and spring well, and insert the locking pin, spring and the retaining pin.
  10. Press the hand hold onto the 1/2" pipe on the short end of the flat bar. Press the reel holder onto the other 1/2" pipe [if you welded carefully, you can radius the inside of the PVC with a knife and seat it all the way down].

Handle 5Handle 4

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