Keyhole Saw Handle from Pipe

The photo from Google Images shows a keyhole saw with a plastic handle.  I had a similar plastic handle on my saw and it broke.  I made a replacement with a piece of pipe.

Step 1 Mark the pipe for length

You can see the blade pattern on my saw.  Once all keyhole saw blades had this configuration. 

I am using 1/2 inch black iron pipe.  I wrapped it with masking tape for easier marking.  The handle needs to be long enough for both the blade and my hand.

Comments

[kelseymh]

Aw, Phil, I'm disappointed!  You didn't use your radial arm saw for any of the steps :-(

[Phil B]

I had a thought in the back of my mind that you might say that.   I suppose I could have  cut the steel with the radial arm saw, but doing it by hand with an angle head grinder was faster.  Thanks for looking and for commenting.

[kelseymh]

:-D  You do know I was kidding, right?  This is yet another really practical presentation of a tool for do-it-yourselfers, and well deserving of the Feature.

[Phil B]

Kelsey,  I knew you were teasing.  Thank you for your endorsement regarding Featured status for the Instructable. 

I just returned from our local hardware store where I looked for replacement blades to fit a keyhole or compass saw, but found none in the style of my saw.  Now I am thinking about a way to fit blades from a reciprocating saw to this saw handle.  That would extend the usefulness of a handle like this greatly with metal and masonry blades as well as wood blades of several types.  Blades for reciprocating saws normally cut on the pull stroke rather than the push stroke, though.  I might be able to make a slot with a cutting wheel on a Dremel tool and place the slot at the front end of the blade so it then cuts on the push stroke.  I am doubtful I can drill the high carbon steel used in the reciprocating saw blades.

[masterochicken]

I'm actually working on a handle for reciprocating saw blades right now. I have a broken saw that I might take the chuck from (if I can ever get it apart), but i actually might just buy one that I saw at my local dollar store.

[Phil B]

Please show us what you develop.

[masterochicken]

I finally got the chuck out and got it to let go of the blade that was in it.

[Phil B]

Kelsey and master...,

I bought a relatively fine tooth blade for a reciprocating saw and managed to make a 1/4 inch hole in it for the bolt shown with this saw handle.  I made the hole with an abrasive cutting wheel in a Dremel tool.  I marked the location and then pressed the wheel into the steel as if I were cutting the sides of a hexagon.  The metal was thin enough that the wheel cut through to the other side relatively easily.  I will probably prepare more reciprocating saw blades this way and will make photos of the steps then.  Anyway, it worked out well.

[masterochicken]

Good to hear. I'm thinking about cutting this chuck and welding a handle to it. My only problem with that is that I have no welder.

[masterochicken]

Of course. I have a few custom tool ideas. Once I make them I might do a slide show.

[kelseymh]

Don't Japanese woodworking saws cut on the pull stroke?  You could use that as your inspiration for a recip-blade hand saw.

[Phil B]

You are quite correct.  Japanese saw cut on the pull stroke, and many people are quite fond of them.  I was thinking one of the common uses of a keyhole/compass saw is to penetrate drywall and then cut out for an electrical switch or outlet box.  It seemed cutting on the push stroke might be better there, although electric reciprocating saws are used in the same way with cutting action on the pull stroke.  I will need to buy a package of blades and experiment.

[Jayefuu]

I like your ibles. I learn something new in every one. Thanks, keep 'em coming!

[Phil B]

Thank you very much.  I am glad they are helpful to you.  I keep thinking I am running out of ideas on which to base Instructables.