— Hello, my name is Damien and I customize my tools instead of actually using them…
My parents got me a round mallet, and I recently bought a bunch of saws and clamps… first thing I did is strip the factory varnish off the mallet and dismantle the bow saw to do the same with its handles. I think I gave a couple taps with the mallet to get a feel for it (it’s quite heavier than my home made one) and I didn’t even try the saw :D
— Is it serious, doctor?
Anyway… The mallet I sanded and refinished with tung oil, it feels much smoother now.
I’m in the process of slightly rounding and re-shaping the saw handles to my hands; they were simply made on a shaper and are bit clunky looking in design (it’s an ECE). Maybe I’ll add a couple subtle chamfers as well, for aesthetics, without compromising strength. I’ve also made a hexagonal mortise to capture the nut at the end of the tensioning bar and eliminate the ugly fan washer.
Believe it or not, in the process I’ve actually used some tools, in particular a card scraper, so at least checked I know how to sharpen and make proper shavings with it.
Edit, august 25:
So, here’s the saw in question, from fine-tools.com
…and some pictures I just took; the handle with quartersawn grain just had the varnish and machine marks scraped off, the flatsawn one is tweaked, finely sanded and now busy absorbing some tung oil (waiting to see how it turns out :).
Overall shape, chamfers on the tensioning side:
Handle shaping, hopefully you can see how symmetric and not so round the original shape was:
Cove and chamfers at the bottom end for a couple fingers when I hold the saw by the blade handle: