The Knew Concepts 5" Fret Saw is
an excellent tool but some people do not like the standard
handle that it comes with.
I really did not have anything
against the handle but wanted to see how difficult it would be
to replace since many people seem to be doing it.
The above is the saw, as shipped.
This is a stock photo.
The standard handle is attached
with a 1/8" rolled pin (also known as a "spring pin") that is
driven into the handle and through a tang on the aluminum
portion of the saw. If you look closely, you will probably see a
bulge on the opposite side of the ferrule where the pin was
I went to my grinder and ground
away the metal of the ferrule where the bulge is.
That allowed me to drive the pin
out of the handle.
After you drive the pin out, this
is what things look like. There's a hole in the tang where the
pin went through.
Looking into the end of the old
handle, you can see that a 1/4" hole was drilled in the center
of the handle and two 1/8" wings were cut into the handle to
allow the tang to slip into the handle.
I made a replacement handle out of
lignum vitae and used a 3/4" ferrule I had purchased from Lee
Valley. I don't show how to turn a handle here - if you can't
turn, you probably won't replace your handle.