Somehow I needed to buy a miter box, but the tool store only had a miter box complete with a miter saw. The miter box and saw were very Chinese, but the urgent need for a miter box forced me to purchase this set. Time passed and I decided to try this Chinese saw at work. After the first pass, the handle of the saw broke and not only broke, but shattered into pieces, and I injured my hand with the sharp edges. Oh, and for a long time I remembered this “wonderful” saw. Some more time passed and I examined the blade itself and decided that it could be useful for precise cuts, and the blade on the saw would make it even. All that remains is to make a new handle for it. And so, the topic of the article is a DIY saw handle.
Making a handle is very simple; for this we need a small piece of plywood 7–9 mm thick, three M3 screws and two M5 screws with nuts, a pencil, a jigsaw, sandpaper, and a drill.
First we need to find out what size the old pen was, for this we collect its fragments and glue them together, maybe not very accurately, only the outline is important to us.
As you can see in the photo, the old saw handle has a weak point, so we will strengthen it in the new handle. Next, we need to make two blanks for a new handle, since it will consist of two halves. To do this, you need to place an old pen on a piece of plywood and draw two contours of our blanks with a pencil. Then, using a jigsaw, you need to cut out two blanks. Then you need to put them together, while ensuring that the dimensions match as accurately as possible. We drill through holes for fastening screws and for mounting screws. We fasten the two halves using M3 screws and process their edges in a yew until they become one whole, without any gaps. It is very good to use sandpaper, since plywood can be easily sanded.
It is also necessary to make recesses for the hacksaw blade and the backing at the place of their attachment.
Then you can put everything together.
After the handle was made, the saw was tested and passed all tests. You can bring back to life not only saws, but also other tools by making handles using a similar method.
In the old days, there were no construction supermarkets; the tool was made individually, and the owner “customized” it to suit himself. Now everyone got lazy: he went and bought it. This will not work with a hacksaw handle; it adapts to the owner’s hand for ease of use in the future.
First of all, we need wood. This can be either a board made of certain types of wood or plywood. I just have a sheet of 12 mm thick 3/4 grade left. This thickness is not enough for a handle, so you will have to fold the sheet in half and glue it together. Cut out two rectangles with dimensions slightly larger than the dimensions of the sample handle. The example is my grandfather’s hacksaw, which I use constantly to cut. Fits perfectly in the hand.
Using a brush, cover the glued sides of both parts with PVA glue. The sides are different - beautiful on the outside.
We compress it with clamps and put it in a warm place. This stage should be given special attention; the surfaces must be adjacent to each other over the entire area.
Let's outline a sample...
...and use it to cut out the future handle.
We process the handle with a file until it “adjusts” to the hand, then we go through it with P320 sandpaper and cover the entire handle with PVA glue.
After the glue dries, the pile will rise. We clean the entire surface with P500 sandpaper and drill holes for the tension screws (first with a 7 drill for the recessed head, then with a 3 drill).
Cover with tsaponlak.
The handle is ready for installation. The longitudinal cut will be made for a specific blade.
He devotes a lot of time to his instrument, which comes out not only of high quality, but also damn BEAUTIFUL. Real works of art.
This time he took up a Soviet hacksaw, which he purchased at a junkyard. Her initial condition was far from ideal. But the quality of the steel from which the canvas was made is much better compared to modern Chinese products.
The old handle was mercilessly thrown away, and the teeth were sawed off, since the middle was sharpened, which led to the bending of the cutting part of the blade. 
A piece of the canvas had to be cut off - it felt like nails were driving it - it was so wrinkled. 
.The dents were knocked out and smoothed out with sandpaper on a block, as well as abrasive blocks. It is advisable to sand “wet”, that is, by wetting the surface to be sanded with water. 
The result is such a shiny blank for the canvas. It will need to be cut to fit the new handle, and an additional hole will need to be drilled (the bottom one will go into sawdust). Drilling such steel with a simple drill is quite problematic. Vladimir got out of the situation using pobeditovoe. 
And finally, the teeth. In order to cut them evenly and consistently, I had to make a special clamp that secures the canvas.
It consists of a pair of halves, between which it is clamped. 
Using a ruler, mark the future teeth on the clamp (with equal pitches)
Using a triangular file, we sequentially cut them down to the piece of wood (this way the height of the teeth is adjusted). 
Another indicator of the quality of steel is that one of the edges of the file has worn out significantly during operation. 
It was not possible to separate the teeth with a cheap plate set - they are harder, so I had to order a good one. While she was on her way through the mail...
The next stage is making the handle. First, a blank of three layers with inserts of bog oak veneer is glued together - for beauty. The outer layers are oak, the inner layers are beech. They were glued together with a simple "Joiner's Moment". 
After the glue has dried, remove the clamps. The shape of the handle was chosen to be anatomical. We print it on the printer and stick it on the workpiece. We select roundings with a Forstner drill 
Next, cut along the contours with a jigsaw 
The inner contour shows the rounding of the handle. Using a knife and rasp, we cut off the corner, welding the edges. 
We finish with files 
Clamping it vertically, we make a cut in the center to secure the blade. 
We cut the blade according to the shape of the handle (I already mentioned this earlier) 
We drill mounting holes (in the handle and in the blade). There are screws and nuts in the handle (brass, by the way), deepen them. 
We sand the handle with sandpaper increasing the abrasive and coat it with oil. 
Let's put everything together.
Even without sharpening, the saw perfectly cuts, or rather tears, wood. And if you sharpen it, 
and even spread the teeth...
The end result was a wonderful hacksaw. You pick it up and immediately want to saw something.
Vladimir put it in his car spare parts. And we can admire the beautiful functional tools, and if the desire arises, we can do something similar. 
In this story we will assemble a simple, but very useful, multifunctional tool. The idea of a handle for holding a file, file or other similar small tool is presented.
If you don’t have a lathe or a familiar turner, then you can easily clamp a brass blank with a diameter of 12 mm in a drill chuck and drill out the central channel. External turning can be done with a file.
Now you need to make a slot in the side wall of the workpiece. This can be done with either a drill or an angle grinder. If they are not there, then you can take a hacksaw and install several blades. The craftsman has a milling machine. 
The holes must be threaded M4. The master applies the initial carving using a regular mortar. But it's too long. Therefore, you will have to use a short one for blind holes. It is ground from debris. This work can easily be done using a drill and a rasp file.
The hydrocellulose varnish has dried well and the final touch in this picture will be to shorten the hexagon screws.
The device is completely ready. This is a multifunctional handle. It can be used to secure a variety of tools that have a round base with a diameter of no more than 4 mm. If you plan to make such a thing for yourself to use only with needle files, then you don’t have to make the side slots. Just one screw is enough.
The option of using a handle with a drill is only suitable in cases where there is no normal drill. And then, only for soft materials such as plastic or wood.
Diamond drill bits come in different types and sizes. With their help, you can straighten a small abrasive stone to the desired shape and sharpen the tool. The slot width is about 3 mm. It is needed to secure a tool with a flat shank. This jigsaw blade is designed for cutting various soft materials when the cut is needed not straight, but curved.
A hacksaw blade for metal is much thinner, so it will be much easier to cut with it. Pay attention to the sharpness of the blade.
If you use the device only to secure needle files, then a knurled screw is ideal. This speeds up the work because you don't have to look for a wrench or screwdriver.
The master always used a scalpel, but never used a breadboard knife. I tried to sharpen the canvas.
You can make a huge number of such attachments. Any shapes and sizes. If you make the tool larger, you can attach full-size files.
