Saw Handle

  • Advertise with us
Project by Jim Jakosh posted 06-04-2016 01:12 PM 1603 views 1 time favorited 22 comments Add to Favorites Watch

I made this handle out of a real necessity. It is the tension handle for my metal cutting band saw. It is one of those saws where the blade takes a twist when going through the guides. If the blade is not tight enough, it gets derailed pretty easily. After about 3 derailments, I had to take action. My hands are so bad that I cannot grab things to tighten or open very well, so, like “hamburger helper” I made a little “handle helper” !!

It is made from a piece of 1” maple. I first cut a hexagon and bored a 2 1/16 hole in it 1/2” deep. Then , using the hex sides as locators, I milled in 6 pockets to house the original lugs on the round handle I milled a slot on top to accept the handle and then turned it round.

For the handle, I cut the piece at 45 degrees for strength and then laid it out and turned the vertical part and carved it to fit . There is a 44 mag casing in the top of the handle ( to cover the construction hole )!

It is finished with clear enamel.

This works so slick now and is painless. I also have my G0555 saw set up like this with an aluminum and steel handle.

Sheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

22 comments so far

View doubleDD's profile


8048 posts in 2283 days

#1 posted 06-04-2016 01:28 PM

This is a slick handle. Probably better than most original equipment ones. Gotta love necessity.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View mafe's profile


11771 posts in 3329 days

#2 posted 06-04-2016 02:17 PM

Looks really nice and most of all it gives you a wonderful grip.
Way to go.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View shipwright's profile


8187 posts in 3038 days

#3 posted 06-04-2016 02:20 PM

Good solution Jim. I can certainly understand the hands thing. Getting old sure ain’t for sissies. :-)

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View HillbillyShooter's profile


5811 posts in 2532 days

#4 posted 06-04-2016 03:08 PM

Great looking solution and much better than many commercially available alternatives.

P.S. Have to agree with Paul’s observation on getting old. My new motto is “Better Living Through Electonics” after having a Resynchronization Defibulator implanted last December.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View John's profile


1374 posts in 1510 days

#5 posted 06-04-2016 03:47 PM

Good looking handle. I understand the hands thing too Jim. Bigger is better for me, don’t like holding small stuff for long now.

-- John, Sunshine Coast, BC, Canada.

View Lucas Mood's profile

Lucas Mood

19 posts in 1316 days

#6 posted 06-04-2016 04:08 PM

Very smart with the angled grain and heartwood corner. Really quite nice. I love functional beauty.

View Luddite's profile


213 posts in 1478 days

#7 posted 06-04-2016 06:32 PM

Jim, Excellent design and construction as always. Like the addition of the 44 casing, adds sparkle to it all.

-- T Loftus -- Just on the edge of common sense

View Cliff 's profile


1381 posts in 1964 days

#8 posted 06-04-2016 07:17 PM

Jim, That is a Beauty!!!!!! Nice to look at and made of attractive wood. Most importantly it will be nice to use. I had a good look at in Zoom and the action looks just right for comfortable and pain free movement in the wrist area. I must look into doing that in the near future, I find winding that existing handle sometimes quite stressful
to the wrist. GREAT IDEA AND GREAT PROJECT!!!!!!!



-- Cliff Australia : Snoring is good. It blows away all the Sawdust.

View Joe Lyddon's profile

Joe Lyddon

10374 posts in 4292 days

#9 posted 06-04-2016 07:37 PM

A VERY COOL handle!

I like, what looks like a sliding dovetail, the way the actual handle was joined to the main body.

You mentioned that you used it on your G0555 bandsaw…
... I also have the G0555 bandsaw… I cannot see where you would need a Handle like this anywhere on the saw!
Maybe you can show us picture of where it goes on the saw? ... just to make it perfectly clear? :)

Thank you very much!

Great job!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View Druid's profile


1933 posts in 3035 days

#10 posted 06-04-2016 07:58 PM

Nicely done Jim, and I’m sure that your hands appreciate the improvement.

-- John, British Columbia, Canada

View luv2learn's profile


2894 posts in 2543 days

#11 posted 06-04-2016 09:11 PM

What’s the old saying, “necessity is the mother of invention”? Nicely done Jim.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View peteg's profile


4435 posts in 3063 days

#12 posted 06-04-2016 09:38 PM

A nice practical answer to one of the problems all us old buggers are starting to face every time we hit the shop floor Jim,
well done Bud

-- Pete G: If you always do what you always did you'll always get what you always got

View  woodshaver Tony C   's profile

woodshaver Tony C

6278 posts in 3593 days

#13 posted 06-04-2016 10:59 PM

All of the above! Great thinking! Nice work!

-- St Augustine FL, Experience is the sum of our mistakes!

View Grumpy's profile


24827 posts in 4091 days

#14 posted 06-04-2016 11:49 PM

Great idea Jim. You should have plenty of leverage now.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Jim Jakosh's profile

Jim Jakosh

21973 posts in 3345 days

#15 posted 06-05-2016 12:00 AM

Thank you all for the nice comments. This handle really helped me a lot!

Hi Joe. The slot is not a dovetail, just a dado. It wall filled with glue and one screw came up from the bottom for insurance.

Here is a shot of the tensioning “handle” on my G0555. I guess I used some nylon in it too.

Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

showing 1 through 15 of 22 comments

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics