Making a saw handle
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I have a D-8 saw that needed a handle. I’ve never made one…did not know you can get templates for them. I traced out the remnants of the existing handle on a cherry board and started cutting the waste away. Things were going quite well. I made some practice holes with my brace and bits to get things figured out for the nuts & medallion. Time to cut the slot for the blade. The original saw had used a circular saw on an arbor most likely. I used a tenon saw. I was going to use a guide and talked myself out of it. Good thing this was a mock up / practice attempt. The cut went sour on me. I’ve decided I can make a real handle though. Will be using a guide on that one though 🙂
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You must be logged in to view attached files.20 September 2015 at 7:05 am #130676OK, other than the angled slot, the handle was looking splendid. I’ve wondered how to get a slot the right size (width) and straight. I just saw a video by John Heisz (searh YouTube for his name to get to one of his channels) where he makes a dovetail saw. The handle is integral with the saw’s “back”. He cuts the slot with the blade that will eventually go into the saw, but he files the teeth to have no set so that the kerf will match the blade thickness. He uses a guide, holding the blade flat but raised off the table a half inch or so, then rubs the saw back and forth along the blade. Took him a long time, but it worked.
I’m sure a lot of saw handles are cut with circular saws with a thin kerf blade. Your handle shows the blade profile (back end of the blade) in one picture and it looks like a small circ saw would get the right curved profile. Tough to do without specialized tools.
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