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Removed the handles from my old stock door frames so i could sandblast,
prime and paint the frames. In removing the handles i had to drill out
the pivot as it was rusted solid. Was able to do it w/o damaging the "D"
shape in the handles. Was thinking of finding 3/8 mild steel rod, hand
filing the ends to 5/16 and dubbing off the sides to form the "D" thus
creating (somewhat) the orig rivet design.
I'm interested to know how the rest of you guys have dealt with this..
Any other ideas??

I drilled and tapped the end where I had ground off the shop head and used a 10-32 machine screw and washer to hold the handles together. It works fine and I can take them off again if necessary.

Thx for the reply, Ace..I destroyed the orig rivets removing 'em-too
much rust. Here's my remedy-Used 5/16-20 x1 carriage bolts, dubbed off
the square near the head and spot welded to the exterior handle. Ground
the threads slightly to give the shank the "D" shape to engage the interior
handle. For the offset in the center i cut down with a tubing cutter a couple of pc of spent brass (.357) and drilled 'em out. CAUTION: dont
try this with live ammo, Gomer!! End result-it fits nice, cant wait
for my canvas from WeeBee!!

Nice work there Rick

Good looking job!