How to Apply a Wood Finish to a Saw Handle

Introduction

Refurbishing or crafting a saw handle can be a rewarding experience, and applying the right wood finish is an essential step in achieving both aesthetic appeal and durability. A well-finished hand saw handle not only enhances the look of your tool but also provides protection against wear and tear, moisture, and grime from frequent use. In this guide, we’ll walk through the process of putting a wood finish on a new or refurbished saw handle, covering essential tools, finishing options, and application techniques.

Step 1: Preparing the Saw Handle Surface

Before applying any wood finish to a new or vintage saw handle, you must prepare the saw handle by ensuring it’s smooth and free from scratches or tool marks. Proper surface preparation ensures the finish adheres well and enhances the natural beauty of the wood grain.

Smoothing the Surface

1. Scraping: Use a small, flexible scraper to remove rough patches and imperfections from the saw handle. A well-sharpened scraper is excellent for getting into small nooks and crannies.
2. Filing: A smooth-cut half-round file (like one of these) is another useful tool for refining the shape and smoothing edges.
3. Sanding: After filing and scraping, sand the surface using progressively finer grits (start with 150-grit and move up to 320-grit). This will help remove any remaining rough spots and prepare the wood for finishing.

Pre-finishing the Saw Handle

Before assembling the saw, apply the first coat of finish to areas that will be difficult to reach later, such as the section where the saw plate meets the handle. This prevents finishing complications after assembly.

Step 2: Choosing the Right Wood Finish for a Saw Handle

There are several wood finish options for a saw handle, each offering different levels of durability, ease of application, and aesthetic appeal. The best choice depends on your personal preference and the intended use of the hand saw.

1. Wipe-On Polyurethane

• Pros: Easy to apply, quick drying, durable, and provides excellent protection.
• Cons: May create a slightly glossy surface, which some users may not prefer for tool handles.
• Buy Wipe-on poly here at Amazon.com

2. Danish Oil or Boiled Linseed Oil (B.L.O.)

• Danish Oil is a varnish often made from polymerized linseed oil or tung oil. Boiled linseed oil is a natural oil that has been boiled, to allow for quicker drying. Most commercial Boiled Linseed Oils aren’t actually boiled, but use chemical dryers.
• Pros: Enhances the wood’s natural grain, easy to reapply, provides a warm and natural feel.
• Cons: Takes longer to dry, may require multiple coats to achieve the desired level of protection.
• Buy Danish Oil here at Amazon.com
• Buy Boiled Linseed Oil here at Amazon.com

3. Shellac with Paste Wax Finish

• Pros: Traditional finish, quick drying, creates a smooth and comfortable grip.
• Cons: Less resistant to moisture and wear compared to polyurethane.
• Buy Shellac here at Amazon.com
• Buy Paste Wax at Amazon.com

Each of these finishes will help protect the saw handle while enhancing its visual appeal. However, wipe-on polyurethane is one of the easiest and most durable options for a functional saw handle.

Step 3: Applying the Wood Finish to the Saw Handle

Once the saw handle is prepped and you have selected a wood finish, it’s time to apply the first coat.

Applying Wipe-On Polyurethane

1. Use a Clean Rag: Dampen a soft, lint-free cloth with a small amount of wipe-on polyurethane. An old T-shirt is my favorite type of rag for wood finishing.
2. Apply in Thin Layers: Gently rub the polyurethane into the wood using smooth, even strokes. This allows the wood to absorb the wood finish while minimizing drips or streaks.
3. Let it Dry: Allow the first coat to dry as per the manufacturer’s instructions.
4. Light Sanding / Scuff Between Coats: Once dry, lightly buff the surface with fine steel wool or a non-woven abrasive pad (these white Scotch Brite pads are my favorite) to smooth out the finish and remove dust nibs.
5. Apply Additional Coats: Repeat the process for two or three coats, allowing each to dry before applying the next.

Applying Danish Oil or Linseed Oil

1. Soak the Wood: Apply the oil generously with a clean cloth, allowing it to penetrate the wood.
2. Wipe Off Excess: After 10-15 minutes, wipe off any excess oil to prevent a sticky residue.
3. Let it Cure: Allow the oil to cure for at least 24 hours before applying additional coats.
4. Repeat as Needed: Apply two or three coats, buffing lightly between each with a white Scotch Brite pad or fine steel wool.

Applying Shellac and Wax

1. Brush on a Thin Layer of Shellac: Use a fine brush or rag to apply a thin, even coat of shellac. See manufacturer’s recommendations for how to thin / cut the Shellac.
2. Light Sanding: Once dry, lightly sand the surface with a white Scotch Brite pad or fine steel wool.
3. Repeat application: Apply additional layers of shellac to achieve the desired build.
4. Apply Paste Wax: Rub in a small amount of wax with a cloth, then buff it to a smooth finish. Our all-natural “Ye Olde Beeswax” wood finish is our favorite!

Step 4: Assembling the Hand Saw and Final Touches

Once the saw handle has received its initial coats of finish, it’s time to assemble the saw and make any necessary final adjustments.

Fitting the Saw Nuts

1. Insert the saw nuts and tighten them securely.
2. Sand them flush with the saw handle using fine sandpaper or steel wool to ensure a seamless look.

Applying the Final Finish

1. With the saw assembled, apply a final coat of polyurethane, oil, or wax to unify the finish and protect any sanded areas.
2. Let any finish dry completely before handling.
3. For a silky-smooth feel, lightly buff the handle with steel wool or an abrasive pad using a final coat of wax, like our all-natural “Ye Olde Beeswax” wood finish.

Final Thoughts: Enjoying Your Finished Saw Handle

A well-finished saw handle not only improves the look of your tool but also enhances its usability and longevity. Whether you prefer the durability of polyurethane, the classic feel of an oil finish, or the traditional look of shellac and wax, taking the time to finish your saw handle properly will make it a pleasure to use.

By following these steps, you can achieve a professional-quality finish that highlights the natural beauty of the wood while ensuring a comfortable grip. So next time you make or refurbish a saw handle, take the extra time to apply a great finish—it’s well worth the effort!

About Tom Calisto

Tom Calisto is an expert hand tool maker, furniture maker, and engineer, with specialty in making historical hand saws, hand planes, and other woodworking hand tools. He has been featured on the the PBS TV show “The Woodwright’s Shop“. He also teaches woodworking classes at Roy Underhill’s “Woodwright’s School” and is a regular contributor to Fine Woodworking Magazine and Popular Woodworking Magazine.