Hacksaw Handle
School Solo Project - Complete
A laminated wood hacksaw handle inspired by Japanese knife construction, combining cherry, mahogany, and walnut to create a grip that promotes steadiness and control.
01 Objective
A class project in DES 340 exploring wood as a material and the tools used to work with it. The goal was to design and fabricate a handle for an existing tool, using joinery and material selection as the primary design decisions. The laminated construction references traditional Japanese knife handles, where alternating wood species create both visual rhythm and a naturally ergonomic grip that guides the hand into the correct position.
02 Inspiration
Inspired by the Japanese wa handle, this hacksaw features an octagonal cross-section that creates a natural pinching point, orienting the hand to promote control and reduce slipping during use.
03 3D Modeling
Using Fusion 360, I modeled the handle at several proportions to evaluate how the lamination pattern and octagonal form would read at scale before committing to cutting the wood.
04 Process
The handle was built by laminating alternating strips of cherry, mahogany, and walnut, then gluing and clamping the block before rough shaping on the bandsaw. The octagonal cross-section was laid out by hand and cut progressively, with the blade slot routed through the center to accept the hacksaw blade. Final shaping and chamfering was done with chisels and hand tools, finishing with progressive sanding through fine grits.
05 Final Product
The finished handle, shaped by hand and finished with Danish oil to bring out the natural grain contrast between walnut, cherry, and mahogany.
