Quoted from Desmodromic:My mistake was assuming that the handlebar on the 1000lb lift cart was 1", like the handle on the 500lb cart. Turns out, it's not. The handle measures right around 28mm or 1.1". So the fittings would not work and I already had a chopped handle.
The brackets were $8 a set and came in two days from McMaster-Carr, which is awesome. With shipping and tax I'm into it for $27 plus a little bit of my time in addition to the cart itself, and it could have ended much more badly given my premature chop-job on the handlebar.
That's funny, I did the EXACT same thing with my pipe cutter, thinking the tubing on both carts was the same diameter! I even had my sleek new chrome boat hinges from Amazon at the ready, and I whistled while I worked. Boy, did I feel like a doof when I realized I should assume NOTHING (just like mama said)!
My solution involved a couple of bulky pipe elbows from Home Depot, which although were a good fit, didn't look nearly as slick as the chrome. They are also angled at 90 degrees, as I couldn't find larger angled ones that fit. I sawed the handle a few inches higher than you did, so pushing and pulling the cart with these elbows attached is doable, but still a little awkward. When not in use, the bottom half of the handle lays flat, while the top portion of the handle stands erect. I'll decline to post photos here, but let's just say I clearly didn't get my degree from M.I.T.
Anyway, I just ordered a set of the brackets that you used here, and while it'll only make it look quirkier than it already does, it will DEFINITELY make the cart slightly less cumbersome to use. I don't have to use it too often, and (thankfully) not a lot of people have to see it.
I'd also add that your photos and explanations are outstanding, so thanks for posting. They'll come in handy!!
Cheers,
Tom