Igloo Cooler Handle

This is a replacement handle for the Igloo cooler in the pictures. I have been unable to determine the exact model.

I broke the original handle and created this replacement. To use it, you will need to break or cut off any remaining plastic from the original handle so that you have only the two telescopic metal pieces on each side that the handle attaches to. There should be a spring loaded thing inside each one with a rectangular plastic protrusion. This is what the replacement handle will push on to actuate the mechanism.

To put this together you will need four bolts and nuts of an appropriate length and diameter, and two screws that will screw in to the underside of the button. These screws will be what pushes against the rectangular plastic protrusions.

I don't have specs or measurements of any of the bolts or screws because I just found them all in my bucket-o-random-hardware. Maybe I'll take some measurements at a later date to make things easier, if it seems like there is any interest. Otherwise, you'll have to wing it.

Please refer to the pictures, as I think they make the installation a lot clearer.

I suspect this may work on other models of Igloo cooler. Just make sure that the telescopic parts are the right distance apart, and the right shape, and that the mechanism is the same. If it works for you and you know your cooler model, I'd appreciate it if you'd send me a message to let me know.

Aug 11, 2024 - Minor Update: I had to reprint this in PETG as my original PLA part warped in my hot car (as predicted). I took the opportunity to add some very small chamfers on the surfaces that will be against the build plate. It acts as built in elephants foot compensation. I also chose to use fuzzy skin on my reprint which looked kind of cool.

Print Settings

Printer Brand:

Anycubic

Printer: 

All-metal Mega

Rafts:

No

Supports: 

Yes

Resolution:

0.3

Infill: 

40

Filament: filaments.ca econofil, stronghero PLA, PLA+ black, red (looks pink)

Notes:

I printed in PLA, but you're probably better off using PETG or something if you think your cooler might be left in a hot car or something.

All the parts are already in the recommended printing orientation. Be careful that your nozzle isn't adjusted too close to the bed. Too much squish (elephants foot) may affect fitment. A raft may be an option if you struggle with this, though I did not use one.

If this design was useful to you, please post a make!