Tool Restoration #7: Old Hand Saw New Handle

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Blog entry by robscastle posted 01-09-2017 04:22 AM 2200 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 6: ST 12 H Restoration Complete...wait there is more. Part 7 of Tool Restoration series Part 8: ST 12 - H Table Saw Claims it first Victim »

I have had this hand saw for quite a long time, and although it has no brand name it always cuts well.
When I was using it some time ago the plastic handle cracked, as it was worth saving then I glued it back together with CA glue and plastic filler dust, it worked again so its life continued.

That was up to yesterday when I was cutting up some PVC pipe throw outs, it broke again

If you are wondering what I was I doing with a load of PVC offcuts I was making some PVC nursery bed for seedlings out of them all.

Here is one of my creations.

The Rosemary Nursery

Now on to the interesting stuff.

The handle parted company yet again.

So I thought its time to go to the rubbish bin, as we headed towards its grave I thought to myself I have enough tools to fix it properly this time.

So disregarding the age of the saw its replacement cost and the fact it would be all possibly beyond eccomomical repair I returned from the bin and set to work fabricating a bew wooden Handle.

I used four pieces of Ply wood, 2×10 mm ply on the outside, and 2×4mm ply inside and then added some laminated ply sheet for the spacer behind the blade.

I cut the profile for the blade spacer on my table saw.

Here is the blade sitting next to the spacer in the handle blank.

the it was simple a matter of drilling locating holes in the blank and its now all is ready to glue up.

Once the glue had dryed overnight it was time to get some shape to it all.

I cut the rough proifile out with a jig saw and then shaped the edges using a disc sander and Osc sander. next I rounded over the the edges with the router, finishing up I used a forstner bit to recess the area for the faseners.

Gave it a sanding all over and then then assebled everything using the same screws.

This was the final result

Gave it a tickle with the triangular file and its back into service again.

-- Regards Rob

5 comments so far

View Joe Lyddon's profile

Joe Lyddon

10961 posts in 5101 days

#1 posted 01-09-2017 04:45 AM

COOL repair & surgical procedure to give it one more life!

Great job!

I’ll bet that handle is more comfortable than the Original! (??)

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View BobWemm's profile


2963 posts in 2975 days

#2 posted 01-09-2017 06:48 AM

Great save Rob.
I have an old saw that requires a new handle also.
Thanks for the prompt.


-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View Blackie_'s profile


4883 posts in 3561 days

#3 posted 01-09-2017 11:22 AM

Nice, very nice.

-- Randy - If I'm not on LJ's then I'm making Saw Dust. Please feel free to visit my store location at

View PhilBello's profile


411 posts in 3016 days

#4 posted 01-09-2017 12:10 PM

Nothing like extending the life of a good handsaw…Nice job!

-- If you want the rainbow, you got to put up with the rain - Steven Wright

View Jay Boutwell's profile

Jay Boutwell

48 posts in 2284 days

#5 posted 01-09-2017 01:00 PM

Hi Bob,

Nothing like having a nice hand saw as they always seem to come in handy more often that not. It is especially nice to have one that cuts and Yes I would fix it too if the handle broke. It has been about 10 years ago since I cut and make one for a hand saw after a framing timber fell on it and it didn’t just crack it but it broke it off. Now It has a nice hickory handle. Jay

-- Jay-- Cabinet Technology

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