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Project Information

I have to give credit to Elkhead Tools for the inspiration on this one. After looking at their top end screw drivers and fret saw handles I decided to try my hand on the lathe. I wanted a dark wood so I went with walnut. However in hindsight I'm not sure walnut is really tough enough for handles in general. Here's a run down of how I did it for anyone that's interested:

Fret saw with handle removed. It simply pulls off.



I used a method that I've used for other handles like lathe tools, screwdrivers, etc. I use brass flare nuts and turn them down after installation. I've made a special tool with a high speed steel bit silver soldered on to turn the brass. I've heard you can also use your hss wood lathe tools but I couldn't bring myself to do it.





I ran into some trouble mounting the brass flare nut and twisted the tenon off on my first try. After redoing it the handle was going to be to short to leave mounted in the chuck like I've historically done. So I drilled the 5/16 hole for the saw and made a pin vise to mount the handle so I wouldn't have to waste as much of the blank.



I brought the live center up for support until I finally had to finish the end. As it turns out I really like this approach as it doesn't waste as much wood and gives you complete access to finish the entire handle.



Lastly I made a spacer to fill the gap and center the handle with the blade (the tang is actually offset on these fret saws). Then I epoxied the flare nut on (is was just threaded finger tight) and finally the saw.



I really enjoy making handles for my tools. For me it makes the tool my own and just feels good in the hand.

Gallery

Comments

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670 Posts
Seems like a job well done, compliments
 

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11,362 Posts
Pretty handle! Great shape, looks comfy to hold and the wood is beautiful. Well done!
 

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32 Posts
Nice job, that is exactly the method we used for our first prototypes. You will enjoy the upgrade.
Gary Benson
Elkhead Tools
 
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