Hacksaw Blade Handle

This Hacksaw Blade Handle is one of several versions of my popular Hacksaw Blade Handle.  It securely holds a standard 10" hacksaw blade and transforms it into a compact, durable cutting tool! It provides a rigid and ergonomic extension to the hacksaw blade, yet it's compact enough to always keep in your toolbox.

Three screws, channels in the handle, and a Blade Latch Screw provide a strong hold on the blade while allowing quick and easy blade replacement.  A large hanging hole at the end makes it easy to hang up your Hacksaw Blade Handle when not in use.

The optional Insert Jig tool can be used to hold the Handle part steady and upright while you insert the brass (heat-set) inserts!  Here is what this new tool looks like:

Here are the Hacksaw Blade Handle versions that I have published and the features that make each version special:

1 - Hacksaw Blade Handle (THIS DESIGN!) https://www.printables.com/model/1253490-hacksaw-blade-handle  (original) compact version; uses brass heat-set inserts to make tool last for hundreds of hacksaw blade changes; optional insert jig makes it easy to install heat-set inserts

2 - Hacksaw Handle (no inserts) https://www.printables.com/model/1470235-hacksaw-handle-no-inserts  compact version; screw threads printed in the handle (no heat-set inserts needed)

3 - Hacksaw Handle With Guard (no inserts) https://www.printables.com/model/1514195-hacksaw-handle-with-guard-no-inserts  ergonomic version with guard; screw threads printed in the handle (no heat-set inserts needed)

4 - Hacksaw Handle With Guard https://www.printables.com/model/1695019-hacksaw-handle-with-guard  ergonomic version with guard; uses brass heat-set inserts to make tool last for hundreds of hacksaw blade changes; optional insert jig makes it easy to install heat-set inserts

For this design...

In addition to the 2-part 3D printed handle, you'll need the following parts to build your own Hacksaw Blade Handle:

1 - Two 14mm long M3 hex socket head cap screws

2 - Two M3 by 8mm (long) by 5mm (max diameter) threaded heat-set inserts (and soldering iron to insert them)

3 - One 10mm (or shorter) M4 hex socket head cap screw - to secure hacksaw blade in holder

4 - A standard hacksaw blade (typically 10" long) - see photos for example

The following photo shows all the parts needed for your Hacksaw Blade Handle...

The following photos show the process for installing the heat-set inserts:

The following photos show the process for assembling your Hacksaw Blade Handle:

The following photo shows this compact Hacksaw Blade Handle next to a much more bulky standard hacksaw frame...

The following photo shows a Hacksaw Blade Handle being used in tight quarters where a traditional hacksaw frame will not fit...

I have provided a STEP (.stp) file to allow modifications to my design.

PrusaSlicer 3MF files have been provided for PETG and PLA.  The PLA files have "PLA" in the filename.

G-code files have been provided for the Original Prusa MK4 for PETG and PLA.

The Hacksaw Blade Handle can be printed in PETG, PLA, PC, or any other material that you can print without warping.  I don't recommend using carbon-fiber or glass reinforced filaments because they aren't needed and because you grip the handle with your hand - which could possibly irritate your skin.

The Hacksaw Blade Handles seen in the photos were printed on an Original Prusa MK4 with Prusament Signal White PETG and FilaCube Red PLA with a 0.4mm nozzle at 0.2mm layer height with a 15% gyroid infill and 3 perimeters (for strength).  Supports are not needed.

Be sure to check out my other designs - including universal key covers and a diverse collection of household accessories and 3D printing tools - on Printables at https://www.printables.com/@PhilCaruso/models AND on MakerWorld at https://makerworld.com/en/@PhilCaruso