Hacksaw Blade Handle
$3.70 Hacksaw Blade Handle
3D
Published 2022-04-07T09:10:45+00:00
A 3D printable light, robust, durable and efficient Handle for a 10 Inch Hacksaw Blade (the blade is ~254 mm X 10mm X 0.9mm), to use the hacksaw blade as a flush cut saw for cutting in difficult to reach places.
This tool was designed because I needed to cut an M3 bolt inside a small pocket of a plastic object, without damaging the plastic part. I already had a metal handle to hold the blade for this purpose. Unfortunately, using it exposes only 1/3 of the blade protruding from the handle. For most jobs this is fine. For the job I had to do it left only 40 mm or so, on the tip of the blade for the actual cutting operation. Needless to say it took more than 1 hour to cut the small bolt.
This design leaves more than half of the blade exposed, therefore a much more usable length for the cutting operation. It works well for flush cutting carbon fiber rods, tubes, metal bolts, plastic parts, wood, etc..
The parts can be easily 3D printed, without any support, on a modern inexpensive 3D Printer. They can be printed with a variety of materials, including PLA, PETG, ABS, ASA and many other types of printable materials.
PETG works very well for this application. It is easy to print. The object should be durable, easy to maintain, and last for a long time.
PLA should work as well as long as the parts will not be used, stored or kept at in a high temperature environment, exceeding ~55 C (~ 130 F).
Please use the following link to view a time-lapse of the object’s production - URL: https://youtube.com/shorts/kvLtIC8ylxE
Recommended print settings with a .4 mm nozzle
- Layer Height: .2 mm
- 3 perimeters or shells (1.35 ~ 1.5 mm)
- 7 bottom layers (1.4 mm)
- 7 top layers (1.4 mm)
- Infill 15%~20%, depending on infill type
Additional items needed for assembly
- 1 x 10” Hacksaw replacement blade
I found the one I used on Amazon: 10" Hacksaw Blades Replacement Bi-Metal 32 TPI High Speed Steel Grounded Teeth, 2 Pack, HT0121-2PC - URL: https://www.amazon.com/HAUTMEC-BI-METAL-Replacement-Grounded-HT0018-2PC/dp/B087DYR359/ref=sr_1_4_sspa?crid=3IM1FAJ8F1T5T&keywords=hacksaw%2Bblades&qid=1649270642&sprefix=hacksaw%2Bblades%2Caps%2C116&sr=8-4-spons&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUExSjI2TU9TWENZVzJFJmVuY3J5cHRlZElkPUEwNjE1NjA0M0NMSU5IOUUyM0s3SCZlbmNyeXB0ZWRBZElkPUEwNDQ2Mzk3VEMyRUNHODhJQ01YJndpZGdldE5hbWU9c3BfYXRmJmFjdGlvbj1jbGlja1JlZGlyZWN0JmRvTm90TG9nQ2xpY2s9dHJ1ZQ&th=1
- 4 x M3-12 (or M3-15) Hex Socket Screws
- 4 x M3 Nuts (M3 locking nylon insert nuts optional)
- 1 x M4-12 (or M4-15) Hex Socket Screw
- 1 x M4 Nut (M4 locking nylon insert nut optional)
Assembly Instructions
Note: The designed tolerance for the nuts is 0.2 mm. It can be useful to drill the holes to precision with a mesh and portable drill. I have good luck drilling/boring the 3 mm holes with a 3.2 mm mesh (included in most metric drill sets,) before inserting the screw. The 4mm hole may also benefit being drilled/bored with a 4mm mesh beforehand.
1- Insert and seat the nuts in the molded hexagonal pockets of the handle. A longer screw (20mm) is very useful to properly pull the nut in the pocket and seat them.
Note: The hexagonal pockets are purposely designed with tight tolerances to retain the nuts long term.
2- Insert the blade in the pocket of the lower part of the handle and align the 4 mm hole. The teeth should face down, away from the finger rest.
3- Insert the handle top and hold securely so the parts remain in place.
4- Insert the M4-12 screw through the handle and blade and tighten lightly.
5- Verify that all the parts are aligned properly and insert the 4 remaining M3-12 screws. Tighten until they are completely seated with just enough force to hold securely.
6- DO NOT OVERTIGHTEN!
| Date published | 07/04/2022 |
| Price | $3.70 |
| Time to do | 275 - 350 minutes |
| Material Quantity | 63 grams |
| Dimensions | 170mm x 35mm x 20mm |
| Technology | FDM |
| Support Free | YES |