Who knows how to make a saw handle

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Forum topic by Marn64 posted 06-09-2016 11:37 PM 786 views 0 times favorited 6 replies Add to Favorites Watch
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296 posts in 930 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 (online now)


5867 posts in 2355 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.

-- In matters of style, swim with the current; in matters of principle, stand like a rock. Thomas Jefferson

View Johnny7's profile


384 posts in 1235 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

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Jim Finn

2680 posts in 3066 days

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


-- No PHD just a DD214 Website>

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23 posts in 2066 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


296 posts in 930 days

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

Thanks for the info everyone!

-- Benjamin, Milwaukee

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421 posts in 2561 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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