Universal extended door handles

The solution

Faced with the problem of not being able to locate a new set of handles to modify, Harrogate and Ripon group engineer Ian Midgley found that it was possible to obtain universal fitting handles.  These accommodate different PZ measurements (i.e. the dimension from centre of handle to centre of lock cylinder) by having a handle that adjusts up/down on the backplate, and by having additional hidden backplates that accommodate different screw centres.  It is reckoned that these sort of handles can be used to replace virtually any size of handle in use.

It was found that a particular make of universal door handle – the “Chameleon Pro XL” – has a completely straight handle design which lent itself to the tip of the handle being sawn off at 90 degrees, and an extension added.  These handles cost around £45/set and are available in several finishes. They are also “sprung” which is important for this particular application as the handle is going to end up a little longer/heavier, and the spring inside the existing door lock may have become weaker over the years.

A central hole was carefully drilled into the end of the handle, and tapped to M10, and an M10 stud inserted.  Aluminium round bar was then drilled and threaded to M10 too, and the whole length of the bar drilled out to reduce weight to an absolute minimum.  It was then primed with Hammerite Special Metals primer, finished in a colour similar to the door (so it doesn’t stand out), and then covered in adhesive lined transparent heat-shrink sleeve with an overlap at both ends.  A plastic plug forced the overlap into the tube at the exposed end, and the overlap at the other end sealed against the end of the handle.

The inside handle was the main concern, but in the expectation our young client would need to get into the house in the future too, the outside handle was modified too – and this can be unscrewed and replaced with a turned aluminium cap – the latter still providing some extra grip.

There were some minor manufacturing issues with the particular set of handles we bought.

1. It was found that one of the supplied components with the handle set had not been threaded in manufacture, so a thread needed to be cut.
2. It was found that the euro cylinder cut out in the handle was about 1mm out of alignment with the corresponding cut out in the inner steel plates – so it needed a few minutes with a Dremel to just grind the inner plate a fraction.

In addition to the above, the Chameleon door handles have a fairly deep back plate compared with some of the uPVC door handles they might be replacing.  The existing lock cylinders in this door were only just long enough.  i.e. it is possible in some applications that the client might need to buy a new lock cylinder of different dimensions.

Optional outside door handle extension

Outside door handle with the cap in place instead, which is secured with an M10 c/s machine screw in the end.

Inside door handle extension

The benefit

Our young client was able to exit the property with ease due to the considerable extra leverage the modification provides.

There was a benefit to Remap too, as this same solution can easily be replicated – and a set of these handles in a common colour such as white could be prepared in advance of any requirement, such that a solution can be provided for a client to try on the first Remap visit.