Hacksaw Handle

If you have one of these low-quality hacksaws with plastic handles, chances are you have faced this problem too. I have two and both handles are broken after just a few years, I think it is mostly because of the plastic handle material which has degraded over time. So I thought why not make a nice handle out of wood and replace it with the broken handle.

Step 1: Cut a Piece of Wood

I simply put the old handle on a piece of wood and draw the shape of it. then cut the outer shape with a jigsaw . For the inner shape, I used my drill press and bored 3 holes with a 30mm spade wood drill bit.

Step 2: Joining the Handle and the Hacksaw Body

Then I measured the body diameter to bore the appropriate hole in the handle. I drilled 2 overlapped hole with a 10mm wood bit and then forced the metal body into the handle.

Step 3: Grinding and Fine Shaping

I used my angle grinder with a wood grinder wheel to shape the main structure of the handle then used a wood file to refine it. In the end, I applied two-step of sandpapers, first with a 40 grit and then switched to 100 grit. It already started to look sweet.

Step 4: Final Assembly

I joined the handle and body together and then drilled a hole for the blade's connecting pin. Tighten the blade and there you go, that's how you make a wooden handle for your hacksaw. Please feel free to ask any questions in the comment section below and also you can check my YouTube channel for more projects like this.