Handle Extender for Pipe Wrench


The Pipe Wrench Handle Extenders are a series of five aluminum pipes that are sized to fit 14", 18", 24", 36" and 48"  aluminum pipe wrenches. They work with steel wrenches too. They have a pin to keep the wrench from falling out, and the pipe is weak enough to visibly bend when you're pulling too hard. They are made of aluminum pipe so they are not too strong and they are lightweight. Finally, I've put in either a knurled or machine textured grip so your hands don't slip. The grip won't wear out, doesn't add to the diameter of the grip, and works well when you have wet muddy gloves. If you’re interested in more information or to purchase call me at 224 715 3699, email Bruce@ErgonomicToolDevelopment.com or you can buy them over the web at the sites listed below although it's a little faster and less expensive if you just call or email me.


We finished the 48 inch pipe wrench extender!  We have strength tests showing good performance up to 750 pounds of bending force.  Here's the 5 minute video of one of the tests. https://www.youtube.com/watch?v=JepWxsj2OLE  If you are interested, shoot me a note at bruce@ergonomictooldevelopment.com or call 224 715 3699 for more information and direct purchase. You can also buy it at http://www.theionixgasstore.com/48piwrhaex.html  It's only 12 lbs., comes in two parts so it's easy to ship and store on your truck.  We kept a reasonable diameter for your grip, and then used a big enough pipe for the wrench end.  To fit the wrench snugly, we shaped the end of the extender, similar to what we did with the 36".  


Below you can see the 48" extender assembled and the two parts.  We also changed some of the retaining pin details.


Below are two photos of the whole range of extenders.  The first is with the wrenches in the extenders, and the second with the wrenches beside the extenders.



And below is a photo of all of the extenders in context.  Going from left to right is the 48", 24", 18", 36", and 14".  The model is 5' 3" so you can get a good sense of how long that 48" extender is.

These pipe wrench handle extenders continue to be a popular solution for reducing wrenching injuries.  Our unique designs for the 36" and 48" extenders allows for a good grip diameter, a snug fit up near the jaws, and a good price.  Prices for aluminum are going up, but I'm keeping my handle extender prices for all the sizes the same for as long as I can.

 

 Ameren came up with these extenders to design a safer cheater bar to help reduce wrenching injuries. The idea is being broadly adopted because they are easy to use, the field guys love them, and they reduce the forces on the body by about 60% which reduces injury and fatigue. Ameren did the design work and testing for 14" 18" and 24" aluminum pipe wrenches, but did not do the calculations for a 36" or 48" aluminum pipe wrench (they did it for steel wrenches).  Two of my fabricators designed the 36" and 48" and we've tested them to 750 lbs. bending force with no permanent deformation of wrench or extender using Ridgid aluminum wrenches.  A 36" pipe wrench is really only about 28" long, and a 48" is about 39" so you can see why people need extenders. 


The pin holds the wrench inside the handle so it won't slide out when in use.
And here's a close-up of the proprietary machine textured handle, and the knurled grip we came up with. You can get the knurl on all the sizes except the 36", and the machine textured grip on the 36".  We tested the two grip styles grabbing the tools wearing wet leather gloves with a mix of snow and mud on the handles and they both performed well, so they are really interchangeable.

For those who want to purchase over the web I have all five sizes on the Ionix site.
 

 There is a full description of the difference between cheater bars and handle extensions below, which I borrowed and adapted from the AGA Ameren presentation.  You'll note the numbers on the amount of improvement aren't the same as the ones I've calculated.  I think you actually get better improvement than they do; about a 60% improvement.
  

Pipe Wrench Handle Extenders

Ameren Corporation is a large gas and electric utility in Illinois and Missouri.  They have developed a handle extension for pipe wrenches in order to lower the amount of force required for wrenching.  This is done by extending the length of the wrench which increases the moment arm so the same about of torque can be supplied by using less force.   Using less force can help reduce injuries associated with wrenching.  For example, you only have to use about half the force to create the same amount of torque using a 24 inch wrench instead of a 14 inch wrench.

Why is the Ameren Pipe Wrench Extender not just a cheater bar?

Cheaters

Unknown material

Unknown length

Unknown wall thickness

Not secured

No anti-slip grip area

No testing performed

Yield strength unknown

Yield before wrench yields?

“Weak” link?

Handle Extenders

Known material

Known length

Known wall thickness

Secured (pinned)

Anti-slip grip area

Testing performed

Yield known

Visibly bends before wrench yields

“Weak” link

Gas utilities are using three sizes of Handle Extenders for three sizes of pipe wrench: 14”, 18” and 24”.  The handle extender increases the length of the handle of the wrench so that you can apply less force to achieve the same amount of torque.  For example:

To tighten a 1” fitting using these three wrenches requires a different amount of force:

14” wrench you need 64 lbs of force

18” wrench you need 52 lbs of force

24” wrench you need 37 lbs of force

But using the handle extenders you can use much less force

14” wrench with 24” Handle Extender you need only 38 lbs of force

18” wrench with 30” Handle Extender you need only 31 lbs of force

24” wrench with 45” Handle Extender you need only 20 lbs of force

That’s 64 lbs down to 38 lbs for a 14” wrench, 52 lbs down to 31 lbs for an 18” wrench, and 37 lbs down to 20 lbs of force for a 24” wrench.

Other benefits of using the Handle Extender

·         The pipe wrench is pinned into position inside the handle extender so the pipe wrench can’t slip causing an injury.

·         The handle extender has a special non-slip grip so you can grip it more securely with less gripping force.  This lowers fatigue for the muscles in your hand, which reduces the chance of injury.

·         The handle extender is sized properly to the wrench so you reduce the risk of breaking the wrench.  A cheater bar can be too long, making it more likely you'll put too much stress on the wrench.

·         The handle extender is made of standard aluminum pipe with known strength, so it is designed to visibly bend before you break the wrench.  It is the “weak link”.

Proper Use

1)      Make sure your pipe wrench is in good condition and the jaws are clean

2)      Insert the pipe wrench into the proper handle extension and secure it with the “D-clip” pin

3)      Grip the handle extension in the non-slip area for the best grip and to achieve the best leverage

4)      Use your company’s recommended wrenching techniques

Improper Use

1)      Don’t hit the handle extension with a hammer or other tool or your hand, use a gradual steady pull or push

2)      Don’t use the handle extension for non-approved tools,  it is designed specifically for pipe wrenches

3)      Don’t pound the extender onto the wrench handle, it should fit easily.  For some brands of wrenches small adjustments may need to be made so the hole in the wrench meets the hole in the extender.  You can do this by cutting a quarter inch or so off the end of the extender. 

  
Tests with the 36" and 48" extender on steel and aluminum Ridgid pipe wrenches have been good up to 750 pounds of pulling force, which is way above what is recommended. The photos below are of an earlier version at 700 lbs., but you get the idea.  If you are interested in these extenders give Bruce a call at 224 715 3699 or email me at Bruce@ErgonomicToolDevelopment.com