Broken handle - any ideas?

[LCHIEN]

Hi Loring,

This is definitely interesting. I need to check if I will get the correct threads on that hanger bolt. The saw is Hitachi (Before it became Metabo) so I am afraid the threads are metric. So I always focused on reusing the original bolt. But let me find that.

Thanks for this idea.

I have a spare original handle for my Hitachi (now Metabo HPT) C12FDH miter saw, You are welcome to have. I'll check the threads. Probably metric

Looks like 10 mm (~9.8) on threads outside dia. and the overall handle length is 9.25"

But frankly, probably easier to make one like I suggested with the dowel than for me to ship this one.

[nicer20]

Hi Loring,

This is definitely interesting. I need to check if I will get the correct threads on that hanger bolt. The saw is Hitachi (Before it became Metabo) so I am afraid the threads are metric. So I always focused on reusing the original bolt. But let me find that.

Thanks for this idea.

[LCHIEN]

See post no. 11 and 12 in this thread https://www.sawdustzone.org/forum/di...bt3x-using-smt where I made a handle like that using a hanger bolt.



To screw the hanger bolt into the dowel lock two nuts onto the bolt threaded part and use some wrenches.
You can choose the size of the dowel and the length and thread sizes of the hanger bolts available at most hardware stores. I bought two overnight from Amazon for 2 bucks, I think. You can thread the bolt into the dowel or cut it with a hacksaw if too long.
Trust me the screw thread in the dowel will be much tighter than the bolt thread in the miter saw there is no danger of unscrewing the wrong end when the miter saw is locked to normal torque to hold it.

[nicer20]

If you split the dowel, tape it back together and drill it the correct size you can use a bolt with a hex head. Chisel out for the head and pins shouldn’t be necessary after you epoxy it back together.

Are you suggesting the dowel split lengthwise??

For splitting the dowel I am thinking of cross-cutting the dowel, using one piece to put the bolt through and reconnecting the cross-cut sections back to rebuild the dowel rod. That way I get the bold embedded inside the dowel handle.

The small dowel pins I mentioned will bear the twisting and shearing forces experienced by the glued cross-cut that I rejoined.

Thanks .....

[capncarl]

Dowel is ok, just make one from oak or walnut that is a hard wood, not soft like store bought dowels. If you split the dowel, tape it back together and drill it the correct size you can use a bolt with a hex head. Chisel out for the head and pins shouldn’t be necessary after you epoxy it back together.

[nicer20]

Hello Friends,

I broke the handle of my friend's miter saw . Unfortunately the replacement part is no longer available. He says it is OK as the saw has been 20 years old but I feel very bad and want to fix it the best way I can.

I tried gluing it together with epoxy but I don't think it is going to hold.

There are two actions this handle performs -

1. turning it to tighten the handle holds the position of the miter saw to desired miter angle. So this action experiences twisting torque.
2. handle is loosened and used to shift the saw to desired miter angle. This action involves sideway bending moment.

My plan is to make a handle using large wooden dowel rod.

Question is should I

(option A): just drill a blind hole, insert the screw and epoxy it in place?

(option B): Or should I cut the dowel in two pieces, insert the machine screw with a through hole and then glue back the dowel pieces? When gluing the two dowel pieces of the handle, I am thinking of inserting a couple of small 1/4" dowel pins to help withstand the forces on the glued joint.

I am leaning towards option B - What do you guys think?

Thanks in advance.

NG