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Woodworking with P. Michael Henderson


Replacing the Handle on a Knew Concepts Fret Saw

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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 driven in.

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.

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