Who knows how to make a saw handle

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Forum topic by Marn64 posted 06-09-2016 11:37 PM 463 views 0 times favorited 6 replies Add to Favorites Watch
View Marn64's profile


173 posts in 210 days

06-09-2016 11:37 PM

Topic tags/keywords: question

Hey everybody,
so 2 days ago, I got a couple Disston saws from my local Restore. Well I have been trying my best, but I couldn’t save the original handle on the 1877 one (the other was a late 40’s early 50’s). The wood is dehydrated, cracked, dusty and every time I’ve tried to epoxy a crack, it won’t set. So I’ve all but given up on the saw handle and was wondering if anyone could make a new one for me or could instruct me how to.

-- Benjamin, Milwaukee

6 replies so far

View JayT's profile


4688 posts in 1635 days

#1 posted 06-09-2016 11:45 PM

It’s not that hard, if you start with a template. Two Guys in a Garage has a bunch of handles scans that will get you started. A drill press and some kind of saw to do curves (bandsaw, scroll saw, coping saw) and you are on your way. Shaping can be done with a router and rasp or even just sandpaper, if you are patient. Quarter sawn lumber is preferred for saw handles.

-- "Good judgement is the result of experience. A lot of experience is the result of poor judgement."

View Johnny7's profile


203 posts in 515 days

#2 posted 06-10-2016 01:41 AM

+1 to JayT’s remarks

Also, well-known LJ saw afficianado Summerfi has a tutorial HERE which you may find useful

View Jim Finn's profile

Jim Finn

2391 posts in 2346 days

#3 posted 06-10-2016 10:08 AM


-- "You may have your PHD but I have my GED and my DD 214"

View Homick's profile


21 posts in 1345 days

#4 posted 06-13-2016 04:51 PM

I have made a handle. The TGIAG is a great place to get a template (make sure you print it without scaling). My process was as follows:

1. Print the template
2. glue it to the wood (I would recommend stock a bit proud of 3/4” up to 1” thick for bigger hands)
3. Drill out the indicated holes. Also drill your holes for the sawplate and nuts
4. Cut your kerf for the sawblade first (because it’s the hardest part to get right and if you screw it up, you didn’t waste much time on it)
5. Start rough removal, leaving about 1/8th” around the border
6. Shape to the border with whatever you have (I use almost ever form of shaping tool you can think of because of all the grain directions and surfaces you are trying to form on a handle
7. Shape the curved edges, rough with rasps, sandpaper strips for finishing
8. Scrap/sand off the paper template if it hasn’t already peeled off.

One of the more difficult tasks I’ve undertaken (no bandsaw or scroll saw here); each step could be chapter in a book. Getting the right shape for your hand is a subtle task … I found using a router for the edge treatment makes it look generic and cheap.

View Marn64's profile


173 posts in 210 days

#5 posted 06-13-2016 08:32 PM

Thanks for the info everyone!

-- Benjamin, Milwaukee

View BigYin's profile


338 posts in 1840 days

#6 posted 06-13-2016 09:36 PM

have you looked on ebay for saw handles ? there are several on tonight

-- ... Never Apologise For Being Right ...

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