Hacksaw Handle (no inserts)

This Hacksaw Handle (no inserts) is one of several versions of my popular Hacksaw Blade Handle..  This version doesn't require heat-set brass inserts or a soldering iron to install them. Instead, the female threads are printed in the 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 Handle when not in use.

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

1 - Hacksaw Blade Handle 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) (THIS DESIGN!) 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 Handle:

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

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

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

Important Notes:

1 - Be careful not to overtighten the M3 screws when connecting the two halves of the Handle - they only need to be snug and can easily be stripped due to the plastic threads in the handle!

2 - The M3 screws that connect the two halves of the Handle are expected to be tight, but if they seem to be a bit too tight, it's ok to add a drop of silicone lubricant or RTV silicone sealant to the screw threads to make it easier to complete this step!

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

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

The following photo shows a Hacksaw 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.

A 3MF file has been provided for Prusa Slicer (has "-Prusa" in the filename) and for Bambu Studio (has "-Bambu" in the filename).

The Hacksaw 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 Handle seen in the photos was printed with Sunlu Gray PETG 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