Footlift handle extension for 441 class machines (low-cost and easy DIY option)

[Uwe]

Lately I've been contemplating the recurring theme of footlift handle extensions for the 441 class of sewing machines (Juki TSC-441, Cowboy CB-4500 CB-3200, Techsew 5100, etc.,) mainly to avoid having to make more of my UX441 handles, which were just much too labor intensive to make.

These footlift handle extensions become a necessity if you install a swing-down edge guide. The original handle interferes with the edge guide and needs to be either removed or extended. 

I think I found a decent solution that is low-cost, almost pretty, and it actually works. Most importantly, you can make it yourself from parts readily available on Amazon or Ebay. For about USD $15, you can make TWO handle extensions and still have one dowel pin left over. I don't think I can come up with a simpler solution, so this is likely my final take on this topic. The parts should be available outside of North America, too - shaft connectors and dowel pins are somewhat generic items. 

Here's the Amazon shopping list (with both blue aluminum and silvery steel shaft connectors) : https://www.amazon.com/hz/wishlist/ls/ISFGAFA3QMTY?ref_=wl_share

The ONLY modification I made to the parts is grinding two flat spots onto the dowel pin, one on each end. This takes about one minute.

Step 1: Remove the existing handle (this may be harder than you think - it took me nearly half an hour to get my glued-and-screwed-on original handle off using Acetone to dissolve the glue)

Step 2: Grind two flat spots on the dowel pin 

Step 3 : Assemble the extension (see images below)

Step 4: Attach original handle to the extension

Step 5: Install extended handle back on machine(use Lock-Tite or similar glue to make it as permanent as you want)

 

Here's a picture of the parts. The dowel pin on top is the original, the bottom one shows the two ground flat spots:

Here are the pictures that show the assembled extension by itself:

 

Here's how the complete assembly looks installed on my Cowboy CB-3200:

 

If you don't think you can handle this DIY task, you can buy the handle extension ( I call it UX441N ) alone or as part of an edge guide kit on my website at http://uwe.store soon. 

Edited February 6, 2020 by Uwe

[dikman]

Well done, Uwe!  You have done all the hard work to show anyone wanting to make an extension just how to do it, and shown how to do it at minimal cost.

[Scoutmom103]

I love the ingenuity and willingness to share with others.

 

[dfrensdorff]

Thanks Uwe!

[Joon1911]

Such a simple solution Uwe,  thank you for sharing.  If I hadn’t already machined a custom extension on the lathe at work, I would be doing this for sure.