Saturday, February 27, 2016

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

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.


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



  1. Most people may not need a powerful chain saw. They can do their yard work on the weekend. They can get away with doing light trimming, mowing, and edging to keep their front and back yards looking nice. If worst comes to worst, they may have to use a hand saw to cut away unwanted branches or go to Home Depot and buy a new McCulloch chain saw.

  2. Nice post. I used to be checking continuously this blog and I am inspired! Very helpful info specially the last part. I take care of such information much. look at more info

  3. This is what gives wood its grain direction. Additionally, a tree grows in concentric layers, producing annual rings. You must pay close attention to these two characteristics -- grain direction and annual rings -- the way a sailor watches the wind. Ignore them, and they'll bite you big time.check over here

  4. Your post is very helpful to get some effective tips to reduce weight properly. You have shared various nice photos of the same. I would like to thank you for sharing these tips. Surely I will try this at home. Keep updating more simple tips like this.  DEWALT Power Tool

  5. Great write-up, I am a big believer in commenting on blogs to inform the blog writers know that they’ve added something worthwhile to the world wide web!. Best Hand Planer

  6. The primary spot that individuals consider when they begin searching for extraordinary woodworking designs is your neighborhood "Do It Without anyone else's help"


  7. When you're tired, you want to relax after a stressful working hours, you need to have time to take care of the kids active.
    Please visit our website and play exciting flash games.
    Thanks you for sharing!
    visit our website

  8. I know this is one of the most meaningful information for me. And I'm animated reading your article. But should remark on some general things, the website style is perfect; the articles are great. Thanks for the ton of tangible and attainable help. thanhtramhuong

  9. The group of woodworkers, while in significance relevant throughout the market when it comes to those beginning in the woodworking sector, has a range of strengths that woodworkers could adhere to in their job. That is Harsh woodworkers as well as Complete woodworkers.SubZero, Viking Freezer Repair in REDLANDS

  10. All the contents you mentioned in post is too good and can be very useful. I will keep it in mind, thanks for sharing the information keep updating, looking forward for more posts.Thanks ui/ux design

  11. The web site is lovingly serviced and saved as much as date. So it should be, thanks for sharing this with us. Gadget personalizzati

  12. Thanks for sharing this post, Your post is very helpful to get some effective tips to reduce weight properly.Visit Hacksaws

  13. As this product continues to impress me, I will most likely move this product up the ranking list. This product contains over 14,000 woodworking plans and projects. These plans are categorized into over 100 different categories that include anything that you would want to build through woodworking.see here

  14. Are wood blinds superior to faux wood blinds, or is it the other way? Learn the facts to choose the right ones with confidence. this website

  15. kids bedding has the tendency to be thinner. In addition, less attention is paid to the design of the bedding. girls bunk bed with slide

  16. This is my first time visit to your blog and I am very interested in the articles that you serve. Provide enough knowledge for me. Thank you for sharing useful and don't forget, keep sharing useful info: wood wrist watch

  17. Ipe decking is rated very highly for being resistant to rot and decay. Ipe wood decking has also been rigorously tested and has a high fire resistance rating without needing any additional treatment.Buy Ipe Direct

  18. Interesting and amazing how your post is! It Is Useful and helpful for me That I like it very much, and I am looking forward to Hearing from your next.. Sunseeker MFT26I-PS-AA

  19. GRAIN: This sort of wood has a grain with tiny pores and is straight and in any event, making it a - > shut grained wood. Basswood is a typical hardwood, that is utilized in blend with uncommon woods like pecan and mahogany. CNC wood router

  20. The best material for wooden shutters depends on personal preference and ability to meet the cost. There are options for all preferences you may imagine. You need to work with a professional to ensure that your expectations on wood shutters are met. writers Choice

  21. Considering there are numerous assortments of wood it very well may be a troublesome decision. They range from various grades of value to various size to different sorts of wood itself. WOODGreen Website

  22. It's superior, however , check out material at the street address. check this link

  23. breaking and evolving shape. This is the kind of thing that specialists have been reading up for a long time is still an all around issue in the timber business. Clearly, nobody would readily pick a deficient piece of wood over a decent, straight one. почистване на дивани

  24. This is a great inspiring article.I am pretty much pleased with your good work.You put really very helpful information
    Hardwood floors

  25. I think this is one of the most significant information for me. And i’m glad reading your article. But should remark on some general things, The web site style is perfect, the articles is really great : D. Good job, cheers garage door repair near me

  26. Occasionally it's not feasible to determine the actual harm till once you utilize your own complete jackets, after which it is as well past due. flooring services

  27. I definitely enjoying every little bit of it. It is a great website and nice share. I want to thank you. Good job! You guys do a great blog, and have some great contents. Keep up the good work. building the surf club north

  28. Thanks for sharing this quality information with us. I really enjoyed reading. Will surely going to share this URL with my friends hardwood flooring

  29. Garden lights and furniture are easy to find online so why not treat yourself this Christmas?led furniture

  30. Thank you ever so for you blog article. Thanks Again. Cool. best lanyard designs

  31. I cannot thank you enough for the blog. Really thank you! Fantastic. heat treated pallets singapore

  32. For the best flames, use wood that has relieved at least a half year after it was parted prior to consuming it.
    continuous veneer dryer