broken handle on my Disston 12 inch saw.
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6 January 2015 at 11:17 pm #123160
i would like some advice on repairing my saw or replacing the handle with a carved reproduction. I love this aw and would like to use it again. Upon inspection I can see that it broke previously and was glued.
It is not museum quality so I figure usability is more important than value as an antique. I would welcome your thoughts.
John
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You must be logged in to view attached files.John,
Saw handle templates are available here:
http://www.blackburntools.com/
and
tgiag.com
Yours looks to be a Disston D4
Look in the Saw Handle Template Library for yours at tgiag.com
There’s a blog tutorial on Blackburn’s site for making your replacement handle.
Best,
Craig6 January 2015 at 11:47 pm #123164I would remake handle
Use a hardwood a fruit wood, would be preferable. Apple, cherry ect.
Tools coping saw/ bandsaw , brace and bit / drill driver, chisels, spokeshave files and rasps/ Dremel ,
and abrasive paper.
Included some power tools to list.
Picture of handle I made out of cherry its a pistol grip bout still fun to do.Attachments:
You must be logged in to view attached files.7 January 2015 at 12:45 am #123166Craig and Mark,
Thanks so much! The power of the community amazes me. Priceless resources I would not likely discover. Thanks much. I will post results.John
John,
I’d suggest you try gluing it back together before you go off making another handle. It may have been glued before, sure, but that doesn’t mean it was right.
Anyways, it looks like a clean break. If it looks right when you just push it together, I would say you’d be OK trying to glue it together.
I’ve used yellow PVA on plane handles and they’ve been fine even though I have used them scrubbing lumber.
Just clean off the break as best you can to get the dirt off and give it a final swipe with some mineral spirits to get the last bit off dust off.
Do a practise run of joining the handle. I suggest putting in a vice, with scrap blocks as necessary to make sure you have the force of the vice is in line with the joint and not making it go off at an angle.
Glue it up in the vise overnight and you should be good to go. Worst case is that you are back where you started.
I’m sure Gorilla Glue or a two-part epoxy would be great too.
7 January 2015 at 3:35 am #123177Jude,
I reached the same conclusion. I decided that I needed the handle in one piece what ever I decided to do. I glued it up with The intent that I would create a new handle. I have some rock hard maple. Wondering what the benefits of Apple or Cherry would be other than nostalgia.
John7 January 2015 at 1:31 pm #123185Yes use any hardwood nothing against that as long as pretty close grained wood used. I probably was being a bit nostalgic about fruit wood if worked on an old Distton would nice now. Maple a good choice Beech also very good, I have also used walnut.
You want to be a woodworker what a better way than to make a handle for saw. Cutting out with a coping saw learn how to control saw. Using rasps and file ect. All good skill builders
You can adjust the shape of handle as you make handle. The better if feels in hand more control you will have sawing.Attachments:
You must be logged in to view attached files.7 January 2015 at 6:32 pm #123216Hi John
I would go ahead and make a new handle it is a fun project I printed out two copies of the Blackburn templates and stuck one on each side of the piece of mahogany I used using PVA glue It was quite easy then to follow the shape. I drilled any though holes I could then used a coping saw, files , rasps, and sand paper to produce the finished handleAttachments:
You must be logged in to view attached files.8 January 2015 at 9:38 pm #123255John – Another source of printable handle templates: tgiag.com
You have nothing to lose by gluing the old handle and use it temporarily, but as others have said, making a handle is a doable project and it can be made to fit your hand.
Cheers
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