Ultralight Camp Saw Handle & Blade Guard - 2 VERSIONS!

UPDATED 18 AUGUST 2024: Added three ultralight smaller versions. 27mm, 25mm, and 23mm fingerholes depending on hand size and glove usage. Printed without supports!

UPDATED 16 AUGUST 2024: I added wider blade guards with a tip protector built in. One for 6in blade and one for 9in.

UPDATED 14 AUGUST 2024: I added V2 with grooves for better grip. I'll print several of these for my packs in due course, but I'm going to add a few features, so if you have a request let me have it!

HANDLE:

I set the fastener holes for a tight fit using one M3x10 bolt and one M3 nut.

I printed in PLA-CF for a prototype. The texture is nice! I considered a fuzzy skin but didn't bother given the CF texture.

I wished I had flipped the handle on the Z so that bolt head was on the top print side — the supplied STL is oriented that way instead of the way I first printed. Flip it as needed to your preferences.

I would consider this light- to medium-duty at best, so I printed with 2 walls and 4 top/bottom layers with 10% gyroid. 0.28mm layers for efficiency. Plenty strong in PLA CF for the uses I would consider reasonable. Strength considerations are dependent on many variables, but I'll probably go with PETG and 4 walls next time just for durability getting knocked around in storage with changing temperatures and such.

I've printed similar bridges without supports, but I did manually add slim trees just on the very outer part of the lip to keep that part as clean as possible. With friction from the CF filament, the blade need two taps of a light hammer to seat.

BLADE GUARD:

I designed the blade guard for a very tight press fit when needed. It's 113mm for use with the 6" blade shown. Printed in 0.28mm PETG for flexibility and repeated use. Next time I have TPU loaded up, I'll print with that for even better durability.

I tried a second one in PLA+ but it came apart along layer lines due to the stress. I recommend resizing up a percent or three as needed. Of course the total length can be rescaled to fit longer blades — or if you write a comment or DM, I can make one to your specs. 

I vaguely reference the model for blade alignment, then adjusted a bunch based on my own measurements and preferences. I started with a straight handle and then shaped a bit from there. I left a thumb rise out because the blade cuts on the draw, still pondering that choice …