How to make mini hacksaw with wood handle

Woodworkers will all have to do some metalwork from time to time. Whether you have to make custom hardware or modify metal to work for your projects. 

A hacksaw is must have tool for any workshop and a mini hacksaw is even better and will be a nice addition to any woodworker's toolbox. And it is fun to make.

I will show you how to make a wooden handle to fit your hacksaw blades. It will be secure in the handle and also be very simple to change. 

This is the mini hacksaw I have had for many years, it has a lot of miles on it and a broken blade. The blade was 10 inches and fits in the handle and can be adjusted to different lengths. I will copy it but change the design of the handle.

I came up with this design for the handle and actually drew it on a napkin. 

                   I transferred the drawing from the napkin onto my                

                     workpiece. I may make some changes as I cut and                  

                   shape it. At the end of this article there will be a template.      

The workpiece was cut out using the bandsaw. I did make some changes and cut it larger than the original because I wanted to make sure the blade would fit correct in the front. Also it it easier to take off wood than to add.

Time to cut the slot for the blade  

                                                              

A narrow slot had to be cut in the handle for the hacksaw blade. To do that a blade was placed between two pieces of wood. A couple of screws are put in to keep it secure. Then some sides are glued on and these will be used as the guides.                                                             

                 

The saw worked fine and gave me a good straight line in the 

bottom of the handle.

                     After the mark was around a 1/2 inch deep I used a larger 

                     hacksaw to cut the slot deeper.              

                    With the new blade in the slot I was now able to glue 
                    in a shim. Remember to push the shim in 
                    enough to keep the new blade firm in the slot. It should 
                    touch the blade.

                   The excess can be trimmed down later when the glue has
                   dried.

A belt sander and a spindle sander are used to clean it up and take away any bandsaw marks. 

                      A small hole was drilled for a nut. The nut was glued

                              in the hole and will be used with a bolt to                                        give adequate clamping pressure for the blade. 

                         A Robertson bolt can be tightened and will squeeze 

                        the wood and clamp the blade. The blade can 

                        now be adjusted to varying lengths.  

                        Don't forget to put in the blade the right way.         

Mini hacksaw template                                                                            

 To test it I cut put a nail in the vise and cut it. The handle was comfortable the tool felt solid making it a very nice mini hacksaw.

Conclusion

A mini hacksaw is a great tool and can even be used for wood.

Because it is simple to make and a good looking tool it would also be nice to make a few and give them away as gifts.

Please let me know what you think, I would like to hear from you.
What projects have you made and had to use a hacksaw?




See Also

Thickness planer     5 easy woodworking projects           Make a compass