Thread: Reducing the set on my tenon saw (and becoming a butcher)

What a journey this has been, and what a transformation.

Last week my pear wood arrived for the handles, and the bolts arrived in the late mail on Thursday, all ready for my Friday off. Yesterday involved cutting out the handle and shaping the handle. I've been reading about rasps, as my current file collection consists of some old steel files and newer Aldi types. How a nice rasp would have simplified the shaping process. None the less, the router with a round over bit took care of the large radiuses, whilst a huge effort with sand paper took care of the minor curves and smoothing the router marks.

As my smallest chisel is 6 mm, I fashioned a 3.5 mm chisel from an unused cheep screwdriver as per Paul's suggestion. It worked a treat in cutting out the recess for the spine. A much better result than my test handle. And I now have a small chisel for other projects too!

20190525_102423.jpg

I had to trim the saw plate to fit the new handle profile, so again used Ian's method, but this time used a flat guide bar which worked perfectly. I figured that rather than continue the cut all the way at the new angle, why not leave a little tail, following the contour of the handle. I think it worked rather nicely.

20190525_102510.jpg 20190525_104639.jpg

Drilling out the bolt holes proved a triumph. Ian had provided me with wonderful detail of how to prepare for and set the bolts. I read it once when he sent it, and again directly before doing anything permanent. I borrowed a 1/2 " spade bit from my dad as I have no imperial bits. It was a little blunt; good thing I've recently acquired my saw sharpening badge, as this allowed me to put a nice edge on the spade bit. the holes were nice and crisp. Following Ian's suggestion, I knocked the bolts in a little way to leave an impression of the square section, and using my new mini chisel, pared and hacked out a rough approximation of a square.

20190525_102316.jpg 20190525_102250.jpg

Finally it was time for a test assembly. The only issue was that I didn't have a split washer driver, and looking around the shed, I really wasn't keen on grinding away the thinnest steel stock I had on hand until it was thin enough. Then it dawned on me, why not simply use some of the blade off-cut. And that's what I did. I fashioned a handle out of some spotted gum, as it's very hard, and should resist the twisting of the blade well (and it did). The "blade" is held in with epoxy, so was left overnight to dry.

20190525_104304.jpg

Whilst the screwdriver was drying, I put on several coats of shellac. It was a little cool yesterday, so gave it a little more time for the alcohol to evaporate before adding subsequent coats. I wrote my name and date below the cow's tongue then applied about five coats in total.

8a3961eb89e86580335f87d31acabd87.jpg

I left it all to set overnight, and bright and early this morning I gave the handle a rub with steel wool, and applied a coat of wax. Good thing my new favourite finishing technique (shellac, steel wool, wax)is so versatile! And because I'm not a complete savage I shaped my new screwdriver so that it was comfortable in the hand.

Final assembly time.

20190525_102551.jpg 20190525_104153.jpg

I think it is simply stunning, and am so pleased with the result. The only problem now is that I can't simply hang it alongside the rest of my saws. This one needs somewhere special. Another reason to forge ahead with my tool cabinet.

This post is sponsored by Ian and Mike, who very generously donated the saw bolts and pear wood. Thank-you, your gift is truly appreciated.

And just because it's nice to remember where it all started.

20190510_123150.jpg

Lance

Well Lance, you definitely get a high distinction for that assignment. The handle looks great, and it's even got a bit of figure to it, which I've not seen in Pear before, it's usually a rather bland, pale wood.

What a fun time you've had these last few months, acquiring knowledge & skills at a head-spinning rate!

Now you're thoroughly hooked on this saw-making business, that saw needs a nice little dovetailer to sit alongside it in the new till you're contemplating.

Umm, make sure to leave a bit of room for a couple more saws, I think you might end up needing it.....

Lance

I have to echo Ian's comments, but it is better coming from him. Also thank you for using the pear (and to Mike) as I am not familiar with it and have not seen it before. I too have been a recipient of Wilkie saw screws and you have done them proud. Actually that reminds me I have some saw screws supplied by Rob Streeper and I will have to come up with a suitable project for those too. Thinking, thinking.....

Well done.

Regards
Paul

Lance,
11/10 that is a fantastic result especially since it was your first saw WOW you should be extremely proud of that effort.
An to think it starts of as a ugly duckling from a chain store.
It really does show you should not judge a book by its cover,
But also re in forces what Ian as been telling us for years to use the saw plate an junk the rest.

Cheers Matt
There’s another one coming isn’t there ??

I’ve had fun following the progress, and what an improvement! Well done.

Thanks for the encouragement everyone. Before any more saws though (and yes, a small dovetail saw is on the cards), I want/need to build a new bench, tool cabinet, wall unit for the lounge, bookshelves, and I have three half finished boxes on the bench at the moment that need to be completed sooner rather than later. I'm not complaining though, how wonderful to have a hobby that can be so engaging.

Lance

Originally Posted by Xfigio

....I want/need to build ..... tool cabinet, wall unit for the lounge, bookshelves, and I have three half finished boxes on the bench ......

Now that list tells me you need a good dovetail saw, like, now!


You may come to rue the day you logged in to this section.
Cheers,

Originally Posted by Xfigio

Thanks for the encouragement everyone. Before any more saws though (and yes, a small dovetail saw is on the cards), I want/need to build a new bench, tool cabinet, wall unit for the lounge, bookshelves, and I have three half finished boxes on the bench at the moment that need to be completed sooner rather than later. I'm not complaining though, how wonderful to have a hobby that can be so engaging.

Lance

So new saw, at your cracking pass one two weeks at the outmost?[emoji849]


Cheers Matt

haha. We'll see.