Help Needed-Sawmaster Power Hacksaw

[Abigalesdad]

I recently acquired another power hacksaw. This one is a Montgomery Ward Model 2403, but it's really a Miller Knuth Sawmaster Model 3100. The saw and stand came 100% painted in a red latex paint. Whoever perpetrated this crime had not bothered to clean anything before painting, so the latex paint came off relatively easily, exposing the original Hunter green. I was going to just clean it and clear coat the original paint, but the original paint color was an easy match so it's turned into a full paint restore.

The saw is missing one part. For those of you familiar with this machine, it is the big gear retainer washer. The washer fits on the big gear shaft and holds the big gear in position. My problem is that my saw is missing this part, and if I'm to make a new one I need detailed dimensions. If there is someone out there that can provide this information I'd be grateful. I included a photo of the big gear on my machine (with lovely red latex paint) and the best photo I can find online that shows the retainer washer on another machine.

Thanks!

Dave

 

[DenisG]

If you can't fit your calipers into the slot on the shaft, then cut a slot in a piece of scrap sheet metal to make a trial gauge. Cut and file until you get a good fit, then measure the slot in your gauge. You could also look for an e-clip from an auto parts place or buy an assortment of them.

 

[lilredex]

If you cannot find an "E" ring that is suitable, just form a piece of flat stock partially on the bench, then finish the bend in place. That is probably how it was done initially as they figured it would never need to be removed.

 

[larry_g]

I recently acquired another power hacksaw. This one is a Montgomery Ward Model 2403, but it's really a Miller Knuth Sawmaster Model 3100. The saw and stand came 100% painted in a red latex paint. Whoever perpetrated this crime had not bothered to clean anything before painting, so the latex paint came off relatively easily, exposing the original Hunter green. I was going to just clean it and clear coat the original paint, but the original paint color was an easy match so it's turned into a full paint restore.

The saw is missing one part. For those of you familiar with this machine, it is the big gear retainer washer. The washer fits on the big gear shaft and holds the big gear in position. My problem is that my saw is missing this part, and if I'm to make a new one I need detailed dimensions. If there is someone out there that can provide this information I'd be grateful. I included a photo of the big gear on my machine (with lovely red latex paint) and the best photo I can find online that shows the retainer washer on another machine.

Thanks!

Dave

Quick look at mine the washer is solid and 1/8" thick and 1.5" OD. Also pointed out (by the pen) in the picture is a setscrew that retains the shaft in the casting. There may be a second setscrew under the guard screw, I don't know. So remove the setscrew pointed out and see of the shaft will slide out.

Small detail on this saw, it cuts on the pull stroke, so the blade is backwards of most saws that cut on the push stroke. Prove it to your self by watching when the saw pulls down on the pressure spring.

Good Luck

lg
no neat sig line

 

[Abigalesdad]

Thank you to those that took the time to respond. Your input was very helpful.

After considerable thought and a little experimentation, I think I have a solution. Here's what I did.

1. I reasoned that a washer of the correct dimensions, if bent similar to a lock washer, might engage the groove in the shaft and with a little tapping, would spiral completely into the groove. Obviously the ID of the washer would be critical, but the same as or slightly larger than the groove diameter of .82". I included a photo of the shaft with groove.

2. I selected a washer from my 'inventory', chucked it into the lathe, and enlarged the ID about .83". I then cut a notch of about 1/4", filed it a bit, and bent it like a lock washer. It wouldn't fit.

3. I then reasoned that the ID of the washer should be at least the OD of the groove plus 1/2 the difference between the OD of the shaft and the OD of the groove. After bending the resultant washer into a lock washer-shape, it should slide over the shaft, into the groove, and with a little tapping, spiral into the groove. I select another large washer from "inventory", performed the above adjustment, and I'll be damned if it didn't work. Following a reshaping to get it flat again, I have what you see in the final photo.

Hopefully this will provide a long-term solution. We'll see.

Dave

NOTE: For some reason, the site is not allowing me to attach photos. I'll try again later.

 

[Abigalesdad]

See the photos of my "solution".

Dave

 

[larry_g]

I would never have guessed that the 'washer' drops into a grove like that by looking at mine. Almost curious enough to to pull the shaft on mine to see how it is assembled because I specifically looked for a split and did not see one. Good job on yours.

On edit; Looking at the picture above I see mine has a zerk recessed into the end of the shaft where yours is a button oilier flush on the shaft so the two shafts may be a bit different..

lg
no neat sig line

 

[Cruzan80]

I know this is an older thread, but by chance, do either of you still have this? Looking for a rubbing of the Sawmaster or Miller-Knuth raised nameplate on the top of the saw (upper arm).