1. Removing handle
Ok, so lets get started. As you can see my saw was in pretty bad condition due to a long term exposure in a very humid areas. Furthermore, the handle was broken so we need to replace that with a 3d printed one. I firstly remove 3 screws, that were holding the handle in place and after that I measure it and started modeling a new one in a solidworks.
2. Modeling in solidworks
A great trick when modeling a copy of any part is to take a picture of most detailed surface and trace the edges of a model in the picture so we can extrude it to a needed height. I also applied a few chamfers and made 3 holes for the screws. Moreover, a 1 mm groove was cut in the middle of the handle so we can fit in the saw blade. After that I just slice it and print it with my printer. The estimated print time was around 3 hours so in the mean time lets clean and polish our saw blade.
3. Sanding / polishing
Firstly, I tried removing the rust with 200 grid sandpaper that did the job perfectly but there was still an unusual oxide layer on the saw blade, so I tried using a dremel tool but there were not much difference so the last idea that popped into my mind was to use a vibrating sanding machine. It removed most of the oxide layer, so we can finally polish it for a nicer look.
4. Assembeling back together
So when the handle was printed I clean the support material and install the handle back to the saw blade. I am really happy with the results, The saw looks pretty aesthetics but the only thing I would change is the thickness of the handle where you hold it. It is a bit too thin for my hand but if you put a hard foam around it should be ok. I hope you like that instructable, please leave some comments if you have any suggestion how would you improve/change it.