I found this small hand saw in my grandpa's workshop and knew I had to save it and bring it back to life. It is the perfect size for my scale of work and would be the first panel saw in my collection. The fact that this is my grandpa's makes it all the more special to me.

Let's get started!!!!

Step 1: How Bad Is It?

Assess the extent of damage and come up with an idea of what you want to replace and/or restore.

This saw handle is chipped and cracked. It is usable as is but I want to make a new handle and give this saw some new life in my collection.

The saw plate has a patina from years of sitting around, as well as rust and the teeth are dull and not completely uniform. I want to clean the plate so I can find out what kind of saw this is and shape and sharpen the teeth.

This is an amazing resto. thank you so much for having posted it. Freaking incredible!
<p>I didn't know that others did this. Recently, I rehabbed an old saw. I replaced the handle with mesquite. I couldn't manage the carvings. Also, 2 of the bolts were missing. Those are hard to impossible to find. Finally found a suitable substitute at a good hardware store (also very hard to find these days). A wire wheel on my grinder brightened up the blade. Tung oil on the handle makes the color of the mesquite stand out.</p>
<p>I was so hoping the whole thing was a restoration. I bet you could have brought that old handle around to looking nice again, scars and all.</p>
<p>Walter,</p><p>I considered doing an original restoration but decided that my goals for this project were to learn how to sharpen and learn to sculpt a new handle from scratch. I've restored hand planes in the past so I have a good idea how the process works, but I have never made a handle from a chunk of wood. I felt like that was more of a challenge and something I wanted to know how to do. Thanks for checking out my project!</p>
<p>You never did mention the &quot;Smell&quot; of the cherry wood. That alone would have made this redo very enjoyable. I was able to turn, on a lathe, some cypress and mahogany chunks that were older than me, gray-headed now, and the smell was still wonderful. I appreciate walter.warren1's concerns, but I'll watch &quot;repairs&quot; to horns later. Thanks for this, I have 2 old Disston saws coming off of eBay as I type. Motivation, of any form, helps calm down the wife, sorta!!!!</p>
thanks for idea
<p>Hey everyone, I just wanted to say thanks to everyone who browsed through my instructable and who voted for it in the wood contest. Thanks to your votes I made it into the top 22 as a finalist. I am sincerely surprised it made it and very excited at the same time. Thanks again!</p><p>-Cory</p>
<p>Great project!</p><p>Although OMGOPENTOESHOESINTHEWORKSHOP</p><p>Hope you never drop a punch on those feet ;)</p>
<p>deluges</p><p>My &quot;workshop&quot; was a balcony of my apartment. Working outside always makes me want to put on flip flops and enjoy the weather :). I tried to wear closed toe shoes when using pointy objects..... Tried </p>
<p>I love the idea behind this Ible. I'd definitely like to preserve objects from my grandparents' home.</p>
<p>Beautiful job, great work!</p>
<p>Good job. I bet your grandfather would love it. Cherry wood is a very nice wood.<br><br>Wlcome to Instructables!</p>
<p>Fantastic job! Your photos and text were very clear and made me want to go searching for an old saw to re-finish! Thanks :)</p>
<p>Thanks everyone for the kind words. It is a joy to use.</p>
<p>You did a wonderful thing restoring your grandfather's saw. I'm sure it will be a family heirloom for generations to come. Congratulations on a fine job. </p>
<p>Beautiful job restoring that old tool. Grandpas (and grandmas) everywhere would be smiling at the before/after pictures. Nice step by step on recreating the handle.</p>
<p>the handle came out real nice! I love restoring stuff, thanks for the great tips..</p>
<p>Very nice job! I am sure your grandfather is smiling, somewhere.</p>
i voted for you mate very good work
<p>appreciate it.</p>
<p>Very nice job, at making a wonderful old tool look new. As an old guy myself, unless the handle is falling apart, you should never replace it. one of the things that make old saws so comfortable to use is the simple fact that the handles are tempered and tuned by use, making them inherently comfortable to the hand. on many old saws, it is common to see the top horn cut down, and reshaped (as in all of my saws, since I have large hands) to fit the owner's hand. This particular saw, however is not so old, since there was a sharp ridge between the flat surface and the rounded edge. I would guess it is made after 1950, when they started cutting corners in manufacturing.</p><p>As for sharpening, you will need four tools to do it right: 1) a long (10&quot; or longer) fine tooth bastard mill file, 2) a medium (6-8&quot;)fine tooth triangular file, 3) a saw set, and 4) a jig for holding the saw blade straight. </p><p>Remove the handle, clamp the blade in the sharpening jig, and run the mill file flat, along the tops of the teeth, until you have all the teeth in line... DO NOT cut below the bottom of the teeth, as you will need them to mark the sharpening file. </p><p>Standing at the front edge of the saw blade, make note of the teeth that are bent slightly to the left. Keeping the far edge of the triangular file straight up, file the teeth from left to right, maintaining an 11 degree angle towards the back right. go back to the front of the blade, and file the right-leaning teeth the same way, but keeping the file angled to the back left. </p><p>Once that's done, use the saw set to restore the set of the teeth to their correct sides. If you want a half -assed job, you can stop here, but I finish it off by gently honing the sides of the teeth, simply by running my whetstone down the sides. This does reduce the set slightly, but makes an infinitely smoother cut.</p><p>It sounds difficult, but it's really only a little tedious, and you'll get a much better job this way than you would from sending it out, and you'll appreciate the tool better.</p>
<p>I completely agree that learning to sharpen yourself is the only way to go. So much more appreciation for the tools you use. </p>
<p>Very nice! I love to see old tools restored, and it's really nice to see every step of the process that produces a beautiful handle like this one. You sure earned my vote. Also, thanks for so many good photos and such thorough documentation. I hope to see more of your work soon!</p>
<p>thanks for the vote :)</p>
<p>Very nice! I have a handful of old saws in my barn that could use a sprucing up like this. Voted for the very well written instructable!</p>
<p>thanks a bunch!</p>
<p>Nice job, well done!</p><p>Mike.</p>
<p>Very well done. I collect panel saws. Usually I refinish and repair the handles to maintain the patina of age. This is certainly an excellent and worthwhile text on making a handle...one of the best I've seen...Thanks, Richard</p>
<p>I thought about repairing the horn and putting epoxy in the small cracks to stabilize it and keep it original, but I wanted the practice of making a new handle since I have never done it before. Same with the saw plate. The patina was nice, but I wanted the practice.</p>
<p>Nice restoration! I have many of my grandpa's tools and work to restore them in my spare time. I know how important they are because I learned so much seeing those tools in grandpa's hands.</p>
<p>Heirloom tools are special no matter the quality. I have already made a small box for my grandmother using this saw to cross-cut the pieces to rough size. I thought it was only fitting.</p>
i voted for you mate very good work
<p>Cheers, Appreciate it. </p>
<p>diykiwibloke..... I used evaporust on this saw. I had some on hand from some hand plane restoration and used a plastic planters box lined with a garbage bag to soak the saw plate. I like evaporust because it is environmentally friendly. I might give citric acid a try too. The one thing I do not like about evaporust is the gray color it seems to stain metal parts. It polishes out well enough though.</p>
<p>Try lemon juice, salt &amp; elbow grease for an environmentally friendly way to remove rust - Lovely job &amp; instructable btw</p>
<p>I think Gramps would be proud of you. :]</p>
<p>I really wish I had some pictures of the saw sharpening process. I tried explaining it below in the comments and probably should have included an explanation in the steps. Maybe I will go back and do that.</p>
<p>Loved all the aspects of the restoration of the handle and the metal saw blade. I was interested in the sharpening of the teeth as you indicated. I would like to find some more instructions on the sharpening of the saw. No one in my community knew how to sharpen a saw.</p>
<p>Where was this ible when I had that hand made saw i trashpicked last year...</p>
<p>I second the motions!</p><p>Reminds me of the story my mom once told me:</p><p>Had to replace the axe blade once and the handle twice, but I still love ole grandpa's axe. lol</p><p>Nice craftsmanship. It's wonderful, and should be admired and, especially, respected.</p>
<p>I am so disappointed that this creative fellow didn't demonstrate how to clean and re-shape and sharpen the teeth of this saw.</p>
<p>Wow- really beautiful work! Inspired by the time and skill that went into restoring this old saw.</p>
<p>Looks Good Great Job- </p>
<p>for anyone who wants to know more about hand saw maintenance check out &quot;the Woodwrights shop&quot; with Roy Underhill here is one on saws </p><p><a href="http://video.pbs.org/video/2365072304/" rel="nofollow">http://video.pbs.org/video/2365072304/</a></p><p>love bringing old tool back into shape good work</p><p>uncle frogy</p>
<p>Wow - looks so good I'd almost be tempted to hang it on a wall now for fear of getting it dirty LOL!</p><p>Have to wonder if there are any Buddy L saw collectors out there :)</p><p>GREAT job and a great way to make sure a piece of family history can be handed down to future generations.</p>
<p>Cory - that's an excellent project. Thanks for sharing. It must be great to own tools from your grandfather.</p>
<p>Beautiful job man! That is some quality wood working. :&not;)</p>
<p>Great Job! Really turned out well. Having worked with a LOT of 'rusty old tools', I usually find it pretty badly 'pitted' in various spots. Yours looks great!</p><p>On a note of levity... Hear about the 100-year-old Hammer? It's had FIVE new handles, and TWO new heads!</p>
<p>Grandpa would be proud of you!!</p>

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More by Hollowground17:Bye Bye French Doors Dovetailed Walnut Box with Curly Maple Inlay Keeping Grandpa's Saw Alive 
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