Not another back saw!

**IanW** · 28th November 2010, 09:30 PM

Nope – Five more.

Don’t ask me why this idea struck, but for some reason I thought it would be interesting to make a set of small saws using some Qld Walnut (Endiandra sp.) for the handles. When I say “set”, of course I am talking about my idea of a set of saws that covers a range of typical tasks. Other folk may find different saws more appropriate to their needs.

I was intending to do these as a WIP, but after getting the blades cut out & the handles roughed out, I pottered away at them in a spare hour here & there, and didn’t get around to taking any more progress pics other than the set of handles set out to show the steps I use going from the sawn-out blank to the final article.
So here is all I have of the making:

1. A pic of all saws together, with handles cut out, slotted, & drilled for the bolts, and all the bolts made. The spines have been slotted & chamfered, but not yet sanded & polished. I do that after testing the final fit. They usually need a little squeeze in the vise to get a firm fit – not too tight, and it should be pretty even along the blade, or it may cause the blade to twist, which rather defeats the purpose....

2. The 5 handles, each at a different stage in the shaping process – you can see the layout lines I use in the early ones. These guide lines are essential for me, otherwise it’s too easy to get the shaping asymmetric, which spoils the look .
Now a quick jump to the finished article, set, sharpened & road-tested. Going down in size, they are:

3. A 350mm blade Disston D8 ‘copy’, 10 tpi, crosscut, blade cut from a Bunnies scraper. The handle is a bit made-up, since I have never had the real thing in my hands, so this is my interpretation - with a bit of license. This is the best ‘discovery’ I’ve made of late. I made one about 6 months ago, after seeing the Wenzloff version, simply because it looked so interesting . It has turned out to be one of the most useful small saws I’ve ever had – don’t know how I got along for so long without it!

4. A 300mm tenon saw, 10tpi rip. The handle is a copy traced from an old pre-WW2 Disston belonging to a friend. Theblade is cut from an Irwin ‘disposable’ (thanks Kevjed!). Once you cut the hardened teeth off, which means a strip about 5mm wide on the ones I’ve tried so far, the sawplate itself is excellent stuff. It’s a fraction thinner than the Bunnies scraper material at a shade under 0.75mm. A shame to think of hundreds of them going annually to landfill when those impulse-hardened teeth dull. Pity about the ugly great hanging hole – I couldn’t get rid of it without sacrificing too much useful metal, so it just has to stay as a reminder of its former ( less glamorous!) life. After a bit of fiddling with the tooth set, it’s tracking beautifully. I’ve given it a very fine set, but it will cut to full depth without binding in dry wood.

Continued...

**Groggy** · 28th November 2010, 09:32 PM

Stop it Ian, stop it!

**IanW** · 28th November 2010, 09:32 PM

And more:

5. A 250mm 15 tpi carcase saw, ), 0.5mm plate from the batch RayG imported (thanks Ray!).

6. A 220mm dovetail saw. It has 15 tpi, sharpened with a bit of fleam. I find this doesn’t affect the ripping action but makes it a bit more ‘dual purpose’.

7. What do you do with the ‘scraps’? Make another saw. The blade is 180mm long, & has 18 tpi. With about 20mm of blade at the toe, it doesn’t have a great depth of cut, but I find them very handy for small jobs.

**IanW** · 28th November 2010, 09:33 PM

Strewth, Groggy - let me finish!

Cheers,

**Woodwould** · 28th November 2010, 10:34 PM

Too, too nice!

(My report is coming – honest!)

**derekcohen** · 28th November 2010, 11:55 PM

Hi Ian

Those saws look terrific - up to your usual standard (as I well know, having two of your saws).

And I know which Wenzloff saw inspired you!

The thought occurred to me that a used Japanese saw blade (I have a Z-saw with broken teeth) may make an interesting dovetail saw as the plates are about .015". The teeth are impulse hardened, but the plate should be OK to file? What do you think?

Regards from Perth

Derek

**RayG** · 29th November 2010, 12:17 AM

Hi Ian,

I really must send you some of that 15thou saw plate....

Haven't looked closely yet, but what are the indentations I'm seeing on the brass back, seems to continue onto the saw plate? Confused?

I'll have a closer look (always like looking at your saws!) later...

Regards
Ray

**IanW** · 29th November 2010, 09:26 AM

Originally Posted by derekcohen

And I know which Wenzloff saw inspired you!

Yes Derek, it's all your fault. It was the picture you posted when you first got yours that set me to thinking. However, I'm glad you did - this is such a useful saw I'm surprised it isn't more popular. How do you find yours?

Originally Posted by derekcohen

....The thought occurred to me that a used Japanese saw blade (I have a Z-saw with broken teeth) may make an interesting dovetail saw as the plates are about .015". The teeth are impulse hardened, but the plate should be OK to file? What do you think?

I have been thinking exactly that for some time. RayG has also suggested trying the thinner plate. If the Japanese blades are like the Irwin blades, the ultra-hard part will only extend to a mm or two below the bottom of the gullets. Cut that off and the remaining material may be of an approriate hardness for saws. It could be the basis of the ultimate small dovetail saw - ~zero kerf!

Cheers,

**IanW** · 29th November 2010, 09:38 AM

Originally Posted by RayG

Hi Ian,
I really must send you some of that 15thou saw plate....

Ray - don't you know better than to supply an addict with the stuff of his downfall?

Well, maybe just enough for one leetle saw..........

Originally Posted by RayG

Haven't looked closely yet, but what are the indentations I'm seeing on the brass back, seems to continue onto the saw plate?

Just reflections, I hope - as you probably well know, it's difficult to photgraph a freshly-polished blade and spine without picking up stray reflections. I tried to set them up in diffuse light to minimise unwanted reflections, but the sun kept dodging in and out of clouds and altering the light unpredictably. Some day I may get around to making a proper light tent, so I can do a real job on the photography...

BTW - I'm not sure I would tackle a bunch of Qld Walnut handles again in a hurry. It isn't bad to work with - bit hard on edge tools, though not as bad as some. However, it is one of those woods that has to be finished through every grade of grit, or you end up with scratches and a spoiled surface. I spent at least twice as long finishing each one as usual. It's quite nice stuff when you finally get there, though & should be durable!

Cheers,

**IanW** · 29th November 2010, 09:46 AM

Originally Posted by Woodwould

Too, too nice!

(My report is coming – honest!)

Don't know what you mean, WW.

Well, I see you have been just lazing about, as usual. You managed to build & finish that COD in a few weeks, while the one I started in January is still a flat-pack. Now you are into mirrors for candles. You really ought to embrace enough of the current century to get some electricity connected to your house, old chap - it could speed up your work .......

**silentC** · 29th November 2010, 09:54 AM

but what are the indentations I'm seeing on the brass back

Looks like the underside of a Colorbond roof to me

Nice saws, Ian. Wish they were mine.

**IanW** · 29th November 2010, 09:57 AM

Originally Posted by silentC

Looks like the underside of a Colorbond roof to me

Your diagnosis is spot-on, Dr. Silent!

**planemaker** · 29th November 2010, 06:42 PM

Originally Posted by RayG

Hi Ian,

I really must send you some of that 15thou saw plate....

Haven't looked closely yet, but what are the indentations I'm seeing on the brass back, seems to continue onto the saw plate? Confused?

I'll have a closer look (always like looking at your saws!) later...

Regards
Ray

Hi Ray. I would like to purchase some saw plate if you have any available . Send me a pm if your interested.

planemaker.

**RayG** · 29th November 2010, 11:19 PM

Hi Ian,

I got time to take a proper look....and...

I'm amazed, all SEVEN saws look just beautiful. Walnut is just beautiful stuff to work, it takes detail very well, is nice and durable, not to mention that it always looks magnificient. Mechanical properties aside, I think walnut is one of the best looking timbers to team up with brass.

You are making me feel guilty for not having had the time to make the saws I planned to, what with one thing and another I haven't been able to make any saws for christmas presents this year. But next year I promise, it will be a different story. The tables will be turned!

Planemaker, if you PM me your address, I'll see what saw plate I can find, I have mostly bright polished 20thou, and some blued 15thou. All 1095 of course.

Regards
Ray

**kevjed** · 29th November 2010, 11:55 PM

OMG, they look wonderful Ian. What a lovely set of saws.
Can you imagine what sort of output you are going to have when you are not so busy in the day job?
I'm taken by this little collection.
Great to see.
All the best
Kevin

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