Replacing Abu Garcia 4500/5000/5500 handles

The Abu handles are 2.5mm thick. What I have experienced is most if not all after market replacement handles are 3.0mm thick. (Such as BPS) Edit: I have a 5000D that is 2.3mm and a newer 5000 that is 3.0mm.

If you try to use a 3mm handle, you'll discover there just isn't a whole lot of threads left for the nut. And with the drive shaft being brass, it's easy to ruin it.

I've been getting by with using a dremel and adding some relief to the bottom of the handle opening so it will allow at least the same amount of threads available for screwing the nut on. On some models may even have to remove a drag washer to allow some leeway for the drag adjustment since the handle is lower and closer to the star drag.

I thought I'd ask here hoping there are more ideas about how to do this without blowing 30 or 40 bucks for a new old stock genuine OEM handle.

Thanks everyone!
Steve

Edited May 20, 20188 yr by Steve1357
Added more data