Saw handle: Back mortise and screw holes

The mortise for the blade’s back was pretty much a piece of cake. I marked it off with a marking gauge on both sides, sawed down the lines, and chiseled it out.

After verifying that everything fit, it was time to drill and shape the holes for the saw screws and nuts. This was sort of a complicated operation, because there are several different sizes of recesses to cut. I started with some small pilot holes in the correct locations. Amazingly, I got them straight working freehand:

The fun part was next, because I got to use both of my braces and two auger bits to cut the recesses for the screws and nuts. Most of the shallow ones are 1/2″ in diameter, but the one for the medallion was 3/4″.

Then I had more holes to drill, because the nuts require one size, the screws another size, and the screw with the medallion needed yet another size. I did a sloppy job with the holes for the nuts, but that doesn’t matter, because it’s actually not a bad idea if they have a lot of slop anyway. I was much more careful on the side for the screws, and that turned out fine:

I test-fit everything. It’s all good. So it’s done except for the finish. I washcoated it this morning. Hopefully this time, the finish won’t take forever.

One thought on “Saw handle: Back mortise and screw holes

  1. I’m glad I found your blog. I have a tenon saw that needs a new handle and I’m going to give it a go. The saw cuts okay, but currently has a plastic handle… nuff said.

    Thanks for taking the time to post your work.

    W. Muse

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