New handle for old saw

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BillK
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New handle for old saw

Post by BillK »

This is a new saw handle that I made. I did the basic design in other software, this was my first time using that software and I did the basic shape and radii there and saved it as an STL. I then imported that STL into Aspire and I used the two-sided machining feature to complete the design by adding the finger grips, an indent for the index finger, and my logo.

This is a Richardson Bros. of Newark, NJ saw that was manufactured between 1878 and 1890. The blade still has plenty of life. The original handle had a crack in it with a nail holding it together. I will keep that around.
Making one of these by hand is a long process. 45 minutes or so of CNC carving got me about 90% of the way.

Next, I have to work on a saw vice so I can sharpen this.
handle toplr.jpg
handle bottomlr.jpg
finger griplr.jpg
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jarm2
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Re: New handle for old saw

Post by jarm2 »

Very nicely done. I have a good saw with a plastic handle and will use your idea to make a new handle out of wood. Great idea.
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scottp55
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Re: New handle for old saw

Post by scottp55 »

Looks VERY comfortable and easy to control...Well Done Bill! :D
LIKING it!
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Re: New handle for old saw

Post by mtylerfl »

I like this idea! I have two saws that could use nice handles like that. Thank you for your inspiration!
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BillK
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Re: New handle for old saw

Post by BillK »

Thanks all. I have 2 or 3 other saws in line for handle replacement. May try a plane tote next though. :D
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New handle for old saw

Post by Bobtail Farm »

inspirational the finger indents.

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Re: New handle for old saw

Post by BillK »

Bobtail Farm wrote:inspirational the finger indents.
Yes, they give it a nice comfortable feel.
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Re: New handle for old saw

Post by Coogara »

It's nice to make something that's practical, and useful in the shed no less. Nice job. Handy finger positions.
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Re: New handle for old saw

Post by Bob Jr »

Bill,
That's one slick handle!
There's a great supply of old saws at our local ReStore. I'll go pick through them and start re-handling a couple.
One question... How did you make such a neat, thin cut into the exact center of the handle in order to insert the blade?
Bob
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Re: New handle for old saw

Post by BillK »

Bob Jr. :

Thanks. I was worried about that cut before I made it. I started by marking and drilling the holes for the saw nuts first. Then I lined it up and cut into the deepest part near the top with a bandsaw with a fence which put me pretty much perfectly on center. It was enough to then use a tenon saw (back saw) to make the full cut to depth. It was a little tight on the blade, so I have a cross cut saw that had a good set and matched the blade width to clean it out to a good fit. Just made it deep enough so that all the holes in the handle line up with the holes in the blade. It helped to have the old handle also.
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Bob Jr
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Re: New handle for old saw

Post by Bob Jr »

Thank you Bill,
It's funny how what seems like the easiest part of a job can be the most distracting for me.
Thank you for your help.
Bob
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Re: New handle for old saw

Post by BillK »

Back at it again....

An old saw, lightly used, but probably left outside for a while. Missing two saw nuts, handle with a crack through. So I had fun changing the design up to custom make a new one. Added the ribbon detail to this one. Really liked using the Level selector for maching the overall face with 1/4 ball mill, then selecting the other level with the ribbon and machining that with a 1 mm TBN. Throw away your rest machining techniques and use the level selector to sharpen up the details. About an hour and a half on each side.

I ordered the new saw nuts, be here next week. So I guess I’ll get the slit in and drill the holes next. This like the first one, feels great in my hand.
Attachments
87E50AD2-6FBB-48B1-957C-2D16B27B4913.jpeg
2311E8F3-0A03-4113-9ACB-AEAB0FA372B8.jpeg
6135FF90-C5E1-4912-97F6-6742652F7C45.jpeg
Mahogany with a coat of oil.
Mahogany with a coat of oil.
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Re: New handle for old saw

Post by gkas »

Very nice job.... Never having done this, how do you slit the handle?

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Re: New handle for old saw

Post by BillK »

gkas wrote:
Wed May 13, 2020 2:54 am
Very nice job.... Never having done this, how do you slit the handle?
It helps to have the old one to know how deep to go. I start the cut with a bandsaw, holding the handle against the fence. I finish it with a handsaw to sneak up on it. Drilling the holes first and trying the blade until you can see the holes aligned, You want it to be a good fit. Being careful with it, you’ll probably spend 15 minutes doing it.
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Re: New handle for old saw

Post by scottp55 »

Nice job Bill! :)
Looks like you'll have a bit more comfort and control with the new one.
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