Old Hand Saw Art

[The-Meerkat]

Old Saw Handle With a New Blade Cut From Scratch.

Man in the Moon

[martyy]

What gauge material did you use? I just my first old saw last week. It was 20ga .

[adbuch]

Old Saw Handle With a New Blade Cut From Scratch.

Very nice job with this one! I like your design.
David

[adbuch]

What gauge material did you use? I just my first old saw last week. It was 20ga .

I don't know what metal thickness he used, but I expect somewhere around 16 ga. to 14 ga. would work well.

David

[The-Meerkat]

Marty, I messed up the original saw blade. It was 20 gauge. (note to self, measure twice cut once). I cut this re-do blade from 20 gauge cold rolled using a Powermax 65 and FineCut consumables. All my settings were exactly from the Low Speed Fine Cut Chart for steel. 30 Amps, 150”/min. I don’t think I could do the teeth without going with Low Speed FineCut.

[The-Meerkat]

David,
Interestingly, since I messed up the original saw blade, I carefully snapped a picture of the old blade. Then imported the photo into Lightburn and did an Image Trace. I resized the whole trace using the original saw teeth distance as my anchoring measurement. Then saved as a dxf, then Sheetcam’ed it and cut it out. I was a little surprised how well the traced, size adjusted image turned out a replacement saw blade that fit the original handle and fasteners perfectly.

[adbuch]

David,
Interestingly, since I messed up the original saw blade, I carefully snapped a picture of the old blade. Then imported the photo into Lightburn and did an Image Trace. I resized the whole trace using the original saw teeth distance as my anchoring measurement. Then saved as a dxf, then Sheetcam’ed it and cut it out. I was a little surprised how well the traced, size adjusted image turned out a replacement saw blade that fit the original handle and fasteners perfectly.

Scott - this looks great! I expect you may have needed to use the 20 ga. to get the steel to slide into the slot in the handle?

David

[kicktillmonday]

Looks amazing! Well done and thanks for posting. Zoomed in on those teeth and WOW your setup cut that perfectly

[martyy]

Yes, looks dialed in. Nice work. Not fun ruining an old blade, but it happens. Always have that weird feeling right before cutting an old buzz saw blade with family history behind it..

[The-Meerkat]

adbuch, I have a few sheets of 16 gauge and tried fitting the handle on it. The handle fit, but it was a very, very tight fit. I figured I’d probably have trouble getting the blade on after I cut it out and applied a couple coats of paint. So I went with 20 gauge that’s the same thickness as the original blade. Less expensive too. It is more “bendy” in the highly cut out areas though.

[adbuch]

adbuch, I have a few sheets of 16 gauge and tried fitting the handle on it. The handle fit, but it was a very, very tight fit. I figured I’d probably have trouble getting the blade on after I cut it out and applied a couple coats of paint. So I went with 20 gauge that’s the same thickness as the original blade. Less expensive too. It is more “bendy” in the highly cut out areas though.

It turned out great! Thanks,
Davod