Rust-Busted Snow Shovel Handle: Heat-Shrink Fix

That “quick” handle fix can become a fight—especially when rust locks a metal grip in place. Here’s how to win and leave your snow shovel better than new.

What you’ll get:

• A step-by-step for freeing a rusted handle
• Cleanup and prep tips for metal
• A durable grip using oversized heat shrink
• Assembly notes to avoid do-overs

Free the rusted handle

• Patience beats prying. If towels slip, upgrade your grip with real gloves for extra bite. A small boost in traction can be the breakthrough.
• Expect hidden plastic collars and burrs to bind the tube. Work them loose before twisting so you’re not fighting two problems at once.
• If it won’t budge, walk away for five minutes. Fresh hands and better leverage often beat more force.

Clean and prep the metal

• Strip surface rust back to bare metal. A die grinder makes fast work on straight sections; on curves, keep the tool moving to avoid gouges.
• Wipe thoroughly with alcohol so the heat shrink bonds evenly. Any oil or dust will telegraph through and can create soft spots.
• Hit fasteners on a wire wheel to remove rust before reassembly. Clean hardware threads in easier and stays put.

Fit heat shrink that looks pro

• Oversized heat shrink works—just test-fit a short offcut first. It should slide on with light resistance before shrinking.
• Shrink in slow, overlapping passes. Don’t park the nozzle in one spot or you’ll blister the tubing.
• If the grip needs to pass through a tight bracket, shrink in stages: first the tube, assemble the handle, then add a second sleeve bridging the joint and shrink again for a clean, locked-in finish.

Heat the right way

• Battery heat guns can take time on large tubing. Plan for a battery swap and keep a steady sweep instead of cranking the heat.
• Stop shrinking when the tubing lays smooth and uniform. Overheating can thin the material and print every imperfection.

The shovel got a tougher, warmer grip and a cleaned-up handle that’s ready for winter. Take your time on rust removal, keep surfaces clean, and shrink in stages for a secure, factory-looking upgrade.