Some of thick Handle bars you can make very cheap!!
It is very easy to make thick handle bars. The cost is minimal. It doesn't require a lot of knowledge. Trust me, if I can do it, anyone can!
This is all the equipment you will need. A hacksaw, duck tape, sand, PVC pipe (the size of the thick handle), steel pipe (to hold the weights), a drill, a large drill bit, post hole cement (other types of cement may be OK), and something to put the mixture together in (a bucket).
The first step is to drill a one or two inch hole, in the center of the PVC end cap. The size should be slightly larger than the size of the steel bar.
The next several step are also very simple. First cut the PVC pipe to the desired length. Put the end cap on it. Place the steel pipe threw the hole in the end cap. You should leave an equal amount sticking out both ends, of the PVC pipe (assuming you are making a dumbbell). Seal the opening with duct tape. At this point, you may want to add a few inches of sand to the bottom of the pipe. The sand should be about a half to a quarter inch above the bottom of the PVC pipe. This will allow you, once the cement has dried, to remove and reuse the end cap. This is a money saver. The end caps cost about as much as a five foot pipe!!
You are now ready to add the cement. If you use post hole cement, first fill the PVC pipe with the powered cement. Next, make sure the top of the pipe is in the center of the PVC pipe. Now, add water. The directions on the sack may be a little unclear about how much water to add. I just keep pouring it in until it runs out the bottom of the end cap. Hold the pipe in the middle or support it with something for a few minutes. It sets up fast. I usually wait a day or two to remove the end cap and use the new thick handle! While the sack says it will dry in fifteen minutes, I think it is better to wait. Usually I have added more water than necessary and the weights involved will put the cement under some stress. Mission accomplished!! You have your thick handle device and it didn't cost much!!
If you are going to make a long bar, I recommend you do it in segments. Add about a quarter of the cement and then add water. Keep doing this until you have reached the top.
I used PVC pipe instead of steel pipe, because it is much cheaper. It is also easier to cut and widely available in many lengths and diameters. PVC marked 1 1/2 has an outer diameter of 1 7/8, 2 is 2 3/8, 3 is 3 1/2, and 4 is 4 9/16. Don't worry about buying too much, it is useful for a ton of workout related products. The dumbbell used in the above demonstration pictures, was made with 3 inch PVC. The other thick handles, in the top picture, were made with 2 inch.
One of the harder items to find are the collars. I would recommend hitting all of the used sporting goods stores in your area. Unfortunately, the pipes and collars that come with new sets are useless, for heavy weights. The pipes are to thin to allow you to apply the collars with enough pressure to hold heavy weights. The collars are cheap plastic and break with heavy weights. I have had good luck getting old, heavy steel, collars from used stores. I suggest using two of them. If you can spend the money, Iron Mind sells excellent ones, with two screws.
Happy lifting!!