Introduction

Many years ago, I picked a mini hacksaw, in a box of tools, which I used for a long time on all kinds of projects where a full-size hacksaw wouldn’t fit. i.e. under the car, engine compartment, construction jobs, home remodeling, etc. It is an indispensable tool for all kinds of jobs. Recently, I had to move my work area, everything went into boxes and is stored in a shed or garage. Now, I cannot find my mini hacksaw. That is why I created this instructable to replace my mini hacksaw until it turns up.

From time-to-time blades or teeth break, what do you do with broken blades? This Mini Hacksaw can use broken blades, slide the blade into the handle, then you are in business. When on job sites I pick up broken hacksaw and sawzall (reciprocating saw) blades. This Mini Hacksaw will hold all types and sizes of blades. How many can say that about their conventional and standard mini hacksaws? There is no shortage of blades when you can use alternatives. I don’t have to buy new blades as often when one breaks. I even use double blades in this mini hacksaw, more on that later.

A benefit of a standard hacksaw is the frame which keeps the blade from bending and add tension. I also created a removable frame to eliminate bending and increase its usefulness.

I made 2 frames, 1 short and 1 tall. I use the short frame mostly for cardboard. This Mini Hacksaw rips through cardboard. Why waste utility blades or scissors (which require resharpening) when you can use used hacksaw blades? The tall frame stabilizes cutting pipes or wide items.

The benefits of this instructable are to:

1) make a useful tool for your toolbox.

2) provide a low-cost alternative to conventional and standard mini hacksaws.

3) make a compact hacksaw to fit into tight areas.

4) use any purpose and size blade.

5) switch out blades easily.

Before I show you how to make a Mini Hacksaw. This is a utilitarian tool, it is not a quality looking tool, it is solely for practical use. Judge this tool for its ingenuity. What it lacks in looks more than makes up in usefulness and practicality.

Step 1: Supplies & Tools

Supplies:

1) 4’’ x 1/2” PVC pipe,

2) Hacksaw blade.

3) Screw & Wingnut.

4) 6-in 22-Gauge Steel Tie Plate or equivalent (optional for Removable Frame),

5) Screw (optional for Removable Frame).

Tools:

1) Heating source, e.g. Hair Dryer, Heat Gun, Toaster Oven, etc.,

2) Drill and bit,

3) Pencil,

4) Gloves,

5) Bench Vice,

6) 2 pieces of wood or metal to squeeze the PVC together,

7) Screwdriver (optional),

8) Files / Sandpaper (optional),

9) Center Punch (optional for Removable Frame),

10) Tin Snips (optional for Removable Frame),

11) Hammer (optional for Removable Frame).

Next Handle.

Step 2: Handle

The handle is made from a Schedule 40, 1/2 in. PVC tubing. Heat at 450 F for about 10 min. (your time may vary). Toaster Oven are not all the same. Use Gloves when handling hot plastic. Flatten between 2 surfaces. I use lattice straps and Bench Vice. Mark and drill a hole into the handle for the screw and wingnut. Assemble and use.

1) Cut PVC pipe to length (this one is 4 in).

2) Use heating source to make PVC pliable. Note: Heated PVC becomes brittle. Do not heat for too long or at high temperature.

3) Flatten PVC.

4) Mark and Drill hole for Screw and Wingnut. (Mark hole just above the blade)

5) Cut the bottom of the PVC pipe. (This cut secures the blade in the Handle)

6) Smooth PVC with File or Sandpaper, (Remove any loose PVC pieces)

7) Assemble.

Next Optional Frame

Step 3: Optional Frame

This Frame increases the usefulness of the Mini Hacksaw. As I said earlier, the frame prevents the blade from bending. I had a leftover tie plate from another project as well as a spare from repairs to my shed sills.

Draw the frame on the plate, cut out the frame, punch and drill holes, assemble and use.

1) Draw frame around blade on Tie Plate.

2) Use Tin Snips to cut out frame.

3) Center punch and Drill holes. (5/32 is standard size for stud or pin hole at the front of the frame. On the small frame I used 1/8 bit, on the large frame I used 5/32 bit). The handle hole will be determined by the size of your screw.

4) File as needed.

5) Add Removable Frame to your Mini Hacksaw.

Next Use

Step 4: Use

Use your Mini Hacksaw. With or without the frame, it is very handy. Cut bolts, tubing, cardboard, etc.

Next Observations & Summary

Step 5: Observations & Summary

Observations

This Mini Hacksaw is a very handy tool. I use it on many different projects because it is universal, able to use any purpose and size blade. It is compact to fit in to a small or standard size toolbox. It fits into tight places and is easy to handle. As I mentioned earlier, doubling the blades, they bend less and can cut more quickly. If you made the Removable Frame the blade doesn’t bend. I use the small Removable Frame mostly when cutting cardboard. Cardboard dulls utility blades quickly, not so with this Mini Hacksaw and Removable Frame. If you are using broken blades, you have given the blades a new lease on life.