Hacksaw Handle With Guard

This Hacksaw Handle With Guard is one of several versions of my popular Hacksaw Blade Handle. This version features a slip-guard band and finger grip bumps, and it uses heat-set brass inserts to provide you with a tool that should last for many years! It securely holds a standard 10" hacksaw blade and transforms it into a compact, very 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. The slip-guard band and finger grip bumps help prevent your hand from slipping forward toward the hacksaw blade or backward off the handle during use (Thanks to arp24 for suggesting this feature!)  A large hanging hole at the end makes it easy to hang up your Hacksaw Handle With Guard when not in use.

An optional Insert Jig tool has been provided to hold the Handle part steady and upright while you insert the brass (heat-set) inserts!

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) 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 (THIS DESIGN!) 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 With Guard:

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 renders show the 3D printed parts of the Hacksaw Handle With Guard and a hacksaw blade:

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The following photo shows all the parts that make up a Hacksaw Handle With Guard as well as the optional Insert Jig:

The following render show the optional Insert Jig tool being used to install the heat-set inserts:

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

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The following photos show the process for assembling your Hacksaw Handle With Guard - note that these photos show the version of the Hacksaw Handle without the Guard, but the process is the same:

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The following photo shows a Hacksaw Handle With Guard being used in tight quarters where a traditional hacksaw frame will not fit:

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

3MF files have been provided for Prusa Slicer (has "-Prusa" in the filename) and for Bambu Studio (has "-Bambu" in the filename) for the Hacksaw Handle With Guard and for the optional Insert Jig tool.

The Hacksaw Handle With Guard 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 - and the embedded fibers could irritate your skin.

The Hacksaw Handle With Guard seen in the photos was printed with Orange Bambu PLA Basic with a 0.4mm nozzle at 0.2mm layer height with a 15% gyroid infill and 3 perimeters (for strength). Supports are not needed.

The Insert Jig tool seen in the photos was printed with Green Bambu PLA Basic with a 0.4mm nozzle at 0.2mm layer height with a 10% gyroid infill. 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