Hacksaw improvement DIY

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Project by mafe posted 12-26-2010 11:25 AM 3184 views 2 times favorited 17 comments Add to Favorites Watch

Hacksaw improvement DIY
A quick and dirty guide…

No rocket launch, but hopefully pleasure in the work shop.

This time it’s more about use than beauty…
I have had this little hacksaw since as long as I can remember, and I like to use it on small jobs. This type of saw is in almost any toolbox in Denmark I think, and handy but not a big pleasure to hold.

So inspired by Rob Cosman, I decided to do something simple yet effective about the problem.

This is what I did.

1. Wrap a piece of rope around the handle.
2. Here the before picture.
3. Make a good knot at the end of the rope so it will not get loose.
4. Now time for some sports tape, cotton tape.
5. Wrap up that handle.
6. And here we are a reborn hacksaw, now a pleasure to use.

The end.

Hope it can be to some inspiration, perhaps even some hacksaws with new handles,

Best thoughts,


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

17 comments so far

View AttainableApex's profile


347 posts in 2802 days

#1 posted 12-26-2010 12:04 PM

i have wrapped things in athletic tape before and it always becomes sticky.
i solved that in my case by doing some whippings with thin string, pretty tedious but way better, i think i did french whipping. there is a bunch of kinds look it up.

-- Ben L

View mafe's profile


11643 posts in 3059 days

#2 posted 12-26-2010 12:50 PM

Hi Ben,
I think it depends on the quality of the tape, but I agree that a more permanent solution will be wrapping, but this one was a just a ‘no rocket’ version, quick and dirty.
Thank you for the input, I had some quite interesting pictures comming up, when I searched on French Whipping…
I will follow your suggestion one day, and make a better wrap.
You can also look under cord wrap, I made some knife handles that way.

Smiles to you and a merry Christmas,

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

View docholladay's profile


1287 posts in 3028 days

#3 posted 12-26-2010 04:12 PM

Before I read the comments, I was going to comment about how my sons (knife collectors) had attempted to use nylon cord to make knife handles. I see you already are aware of that technique. Personally, I think I would have had to figure out a way to make a wooden handle for it. Not just because this is a woodworking website, but mostly because I just prefer the look and feel of wooden handles on my tools. I even removed the old plastic handles off of some of my tools and made new handles from wood for that reason. You could make handle (2 halves) and then sort of carve out a groove that the bent wire handle would fit into. Then epoxy it into place making a sort of sandwich. Finally, do some final shaping with rasps and files to make it comfortable and it would be there forever.


-- Hey, woodworking ain't brain surgery. Just do something and keep trying till you get it. Doc

View mafe's profile


11643 posts in 3059 days

#4 posted 12-26-2010 05:16 PM

Doc, you just posted my thoughts, I just said to Napoleon I would repost this with a wooden handle, so we are the same. And acually I regerded to have postet it as a project after…
But I will make a wooden and put in the post.
Just thought it was usefull, since it was so much better to use after I did the wrap.
Best thoughts,

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

View WoodenFrog's profile


2737 posts in 2883 days

#5 posted 12-26-2010 05:57 PM

Mads, I just got a couple of these saws( with bent wire handles) at a flea market.
They are great but I like your hande idea, might have to try this, can’t wait to see your work in wood.
I also got my first little plane a Stanley 101, I think?
I too you, do small little projects. Hence small little hand tools are what I like.
Have a Great Day—Robert

-- Robert B. Sabina, Ohio.....

View lanwater's profile


3111 posts in 2904 days

#6 posted 12-26-2010 06:36 PM

Always full of ideas and always nice to read!

-- Abbas, Castro Valley, CA

View patron's profile


13600 posts in 3311 days

#7 posted 12-26-2010 06:39 PM

one mistake on 380 days
is ok
so long as you correct it
do so soon
i’d hate to be you
when caroline
asks you
about an ankle bracelet
(electronic probation)
in bed lol

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View TopamaxSurvivor's profile


18250 posts in 3645 days

#8 posted 12-26-2010 06:43 PM

What do you do with that little hacksaw?

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Jim Jakosh's profile

Jim Jakosh

20317 posts in 3075 days

#9 posted 12-26-2010 07:06 PM

Nice work, Mads. It it always nice to improve things especially if you use them often. I too was thinking of a wooden handle with two halves grooved out for the wire frame. Another thought would be to make a mold around it with about 1/8” clearance all around and pour if full of epoxy and then carve and sand the contour to fit your hand- or a combination of wood and epoxy. The syy is the limit on a thing like this.

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

View scrappy's profile


3506 posts in 3400 days

#10 posted 12-27-2010 06:28 AM

Great idea for this little saw. I use mine a lot and the handle sucks! Not sure if I should wrap mine now or try to make wood ones like suggested. I have more then one…..maybe do both and see which I like better?

Keep up the inspiration.


-- Scrap Wood's the best...the projects are smaller, and so is the mess!

View Napoleon's profile


788 posts in 2779 days

#11 posted 12-28-2010 12:11 AM

Mads my friend, its nice to see the rob-inspiration also have hit you a bit my friend :D

Good ideár with the handle.

-- Boatbuilder&blacksmith

View againstthegrain's profile


117 posts in 3722 days

#12 posted 12-28-2010 06:23 AM

Love the idea. Will have to try it out on my hacksaws!

-- Anchul - Warrensburg, MO: As a Pastor, I am just trying to get closer to Jesus. He was a woodworker too.

View mafe's profile


11643 posts in 3059 days

#13 posted 12-28-2010 02:30 PM

Hi guys,
Yes I can see after all that it was completely hopeless ‘doubted my ida for a moment’...
So I guess I will not change the post, just make another version.
againstthegrain, I’m truely happy for that.
Napoleon, yes my friend your Rob saw inspired me to do things simple, when Bob Crossman can, then I can…
Scrappy, do both and tell us the difference it would be super.
Jim, I love you man, not only do you suggest something eles, you also come with solutions. I was also thinking of the shell solution, and will try this when I have time, what is important is just that the saw still flex, so the blade tension are not to loose. The Epoxy thing is still to come, I have some of this stuff in two bottles in my workshop, but have never tryed to play with that…
topamax, saw! LOL. Just used it when I made my daughters little greasebox, for cutting the brass inlay. I like a small saw for delicate work.
David, thank you for the comfort, yes we can be allowed to do mistakes, then we learn, and I still have plenty to learn, you have learned me a lot, about how to be a better person, I try harder to find my patience since I meet you here. I laugh Caroline can be a tough woman, but full of heart, so we will see.
Ian, smile, yes this old brain never stop.
Robert, congratulation with the little 101, it’s a fine little plane, when you tune it and sharpen it proper, it will bring you many good hours.
Best thoughts from my heart, and thank you all,

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

View TopamaxSurvivor's profile


18250 posts in 3645 days

#14 posted 12-28-2010 08:55 PM

I don’t think I have ever seen a hack saw that small or the small baldes.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View stefang's profile


15881 posts in 3304 days

#15 posted 12-28-2010 11:50 PM

I have a little saw just like yours Mads. My youngest son made it in ‘sloyd’ at school when he was 12 years old. I like your tricky quick fix on it, so I will have to do the same.

-- Mike, an American living in Norway.

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