Reinforced handle using bushings

[rob streeper]

As part of the debate on the design of saw screws I proposed to insert bronze bushings into the holes for the screws. I have finally gotten around to doing it.

The first step is to cut the three-stepped recesses to accommodate the bushings. Fortunately my counterbore set contained all of the needed sizes. The needed degree of precision in fitting here is not very high as the bushings will be secured with epoxy.

cutting three step counterbore 2.jpg

First one done.

first three step counterbore.jpg

Cutting the bearing seats was a trial and error process but only took about 30 minutes.

test seating of bearings.jpg
Now for some epoxy and wait.

waiting for epoxy to dry.jpg
And done.

Bearings secured.jpg
Obverse:

obverse bearings secured.jpg

I then test mounted the stock to the blade having under-sized holes already punched and reamed the first hole to size. I inserted one screw and proceeded to ream the second hole, inserted a screw and reamed the third.
I tested the saw by using it to cut a 2"X4" piece of southern yellow pine without using the saw screw nuts. No problems and the blade was very tightly held in the handle with no perceptible movement of the plate relative to the handle.