Back to Shopmade Tools




New Handles for the Knew Concept Saws




In a review of the Birdcage version of the KC fretsaw I mentioned my preference for a handle that was longer than the original. Here you can see the KC handles alongside one I made ...




The reason was that the new fretsaw balanced better using two hands rather than one ..


I decided to replace the handles on the Birdcage fretsaw and the coping saw.



There were a few nice pieces of Jarrah in the scrap bin …



For this pictorial we shall replace the handle of the coping saw. The fretsaw handle is exactly the same.



The first task is to remove the old handle. Use a beater chisel to punch through the thin steel of the existing ferrule …





Once it has been peeled away, you will discover that the handle is held onto the frame with a pin. Punch this out from the rear …



The tang is tapered …



The tang will seat in a tapered mortice. This will be created with a drill. Choose a drill bit that is the same thickness as the tang …



Mark the widest point of the tang …



Begin by drilling straight down, then pull the drill bit over to one side …



Pull it over to the other side, and you will have drilled a wedge-shaped mortice. Straighten it up a little, as needed.



The tang is epoxied in. I used 5-minute two-pack epoxy. Ensure the handle and frame are square with one another …




Here is a comparison of handle sizes, old and new …






Completed refit …


One more …






Regards from Perth

Derek

March 2014