A new backsaw

**Woodwould** · 20th January 2011, 03:06 PM

To me, edge tools (and I include saws) are akin to car tyres; they wear down and they require frequent checks and maintenance, but they're a necessity nonetheless. Also like car tyres, edge tools are made from materials of varying qualities that either provide longevity, or performance, but rarely both.
I've never really enthused much about either commodities and have steered away from whitewalls, raised white lettering, and the glut of fancy tools that we are now swamped with – unless they offer me a distinct gain in performance or comfort.

I think part of my unenthusiastic view of the majority of cabinetmaking tools is that I have decidedly large hands and I have never been able to put a tool straight to work without re-handling it or performing some other major surgery to prevent the tool causing cuts and blisters. The strengthening rib alongside the handle of every metal bench plane I have owned has caused blisters and/or infections on the heel of my right hand and the blade cuts the skin off the top of my thumb knuckle. To address these issues, I make deeper handles, thus moving my hand upwards and backwards and I remove the top inch from all new blades.

Chisels have to be re-handled with longer, fatter items to place the end correctly in the palm of my hand and the increased girth makes it possible to close my fingers around the handle without distressing my finger joints.

Saw handles too are a problem: The minimum action I take is to cut the horns off so the lower one doesn't create a blister in the heel of my hand and the top one doesn't create a blister in my thumb web.

Spear & Jackson saw handle with the horns trimmed off.

The saw handle above is large by comparison to many off-the-shelf saws I've tried and didn't require too much trimming to make it useable; however it's quite thin in cross section. This saw was a relatively recent eBay purchase for my woodworking renaissance (all my old work tools were dispersed when I retired).

I joined RayG's 'saw steel and brass back' bulk buy on the forum, fully intending to make myself a couple of useful saws, but as yet, haven't got round to doing anything with the materials. Then one day while chatting with IanW, he very kindly offered to make me one of his fine saws. We discussed the saw's purpose, tooth count, handle size and type of wood etc. I was particularly taken by the handle of a saw that Ian had posted an image of on the forum; it was Rock Oak. When talking with Ian, he was doubtful if he had any Rock Oak remaining and asked what alternatives I would be happy with. My response was, as this would be an Australian saw through-and-through, I would like the handle to be an Aussie timber of his choosing. Before I knew it, a beautiful new saw arrived in the post.

IanW's incredibly fine and generous gift.

The saw has an eleven inch canted 15 TPI blade, filed with Ian's 'secret' tooth profile (a 5° rake angle, with a bit of fleam – a hybrid rip/crosscut) and a stunning Rock Oak handle! I told Ian I have large hands, but I don't think most people realise just how large hands can get!

I tried the saw out on the William and Mary chest of drawers I posted elsewhere on the forum, but, although immaculately made and finished, I just couldn't get to grips with the handle and therefore my cutting experience with the saw is limited. What I can report at this stage is that the blade is thin and cuts very cleanly in hardwood and softwood.

"Why…" I hear you screaming, "…have you not made a replacement handle for the saw in all this time?" Well, I feel if I'm going to replace the handle, then I owe it to the saw and to Ian to make it from Rock Oak and therein lies the rub: I have made several enquiries on the net and at last year's Timber & Working with Wood Show in Melbourne (where I thought I had a lead on some), but nothing has transpired as yet. If I can't lay my hands on some suitable Rock Oak soon, I will make a replacement handle, albeit temporary, from another Australian species.

'Big' handle and bigger hand.

I finally got round to making a replacement handle for the Spear & Jackson saw from a piece of Apricot. It's 7/8" (22.2mm) thick and much deeper in the grip.

New Apricot handle.

With Ian's saw laid atop of the Apricot handle; the disparity in size is quite apparent.

Ian's saw above the Apricot handle.

The re-handled S&J saw.

Apart from the sheer embarrassment of not yet posting my findings on Ian's saw, I really want to get it to a useable state, so if anyone has a piece of Rock Oak, of minimum dimensions 8" x 5" x 7/8" (200mm x 130mm x 22mm) and is willing to part with it, I would appreciate a P.M. from them.

I am humbled by Ian's workmanship and munificence and will report back on the saw, one way or the other, in due course.

In the mean time, if anyone else similarly suffers the ignominy of unfeasibly large hands (size 10 latex gloves regularly burst), and would like to replace their saw handles with something a little larger, I've uploaded the pattern I used to make the above outsized Apricot handle.

**jmk89** · 20th January 2011, 03:23 PM

WW
I have a big mitt too, but in my case it is a function of longer-than-usual fingers (rather than larger in all directions). So my response may well be off-topic. For me, a solution is often to thicken the handle - I picked this up from a golf pro who corrected a problem (not the only one) that I had by recommending that I thicken the grip of my club.
If you have long fingers, a thicker grip can help.
Before replacing my 3/4" thick saw handles with fatter ones, I tested the theory by wrapping tennis handle tape around my saw handles. That improved my sawing & comfort dramatically. So now I use 25mm or fatter for saw and plane handles & I find I cut straighter and with more comfort .
A bigger handle may be what you need, but it is worthwhile considering a fatter handle first

**Claw Hama** · 20th January 2011, 03:31 PM

Yep, thicker handles are far more comfy, I replaced a handle on an old S & J 12" tenon and it sits just on 25mm thick, so much more comfortable.

**Woodwould** · 20th January 2011, 03:35 PM

Originally Posted by jmk89

WW
I have a big mitt too, but in my case it is a function of longer-than-usual fingers (rather than larger in all directions). So my response may well be off-topic. For me, a solution is often to thicken the handle - I picked this up from a golf pro who corrected a problem (not the only one) that I had by recommending that I thicken the grip of my club.
If you have long fingers, a thicker grip can help.
Before replacing my 3/4" thick saw handles with fatter ones, I tested the theory by wrapping tennis handle tape around my saw handles. That improved my sawing & comfort dramatically. So now I use 25mm or fatter for saw and plane handles & I find I cut straighter and with more comfort .
A bigger handle may be what you need, but it is worthwhile considering a fatter handle first

Thanks. Actually I did increase the Apricot S&J replacement handle thickness from the stock 3/4" up to 1" initially and found it too thick, hence the final thickness of 7/8".

**kevjed** · 20th January 2011, 04:17 PM

I'd love to say.....looking good WW but my eyes are failing me as I can't see any images yet. My guess is that you"ll load them later?
Thanks for that Template....I have to make a saw for a mate with big hands.
All the best
kevin

**Phil Spencer** · 20th January 2011, 04:24 PM

Originally Posted by kevjed

I'd love to say.....looking good WW but my eyes are failing me as I can't see any images yet. My guess is that you"ll load them later?
Thanks for that Template....I have to make a saw for a mate with big hands.
All the best
kevin

Can't see the pictures either WW

**Woodwould** · 20th January 2011, 05:14 PM

Sorry, but the absent images seem to be due to the new regime - they're in my album and awaiting moderation before they become visible!

Hopefully a moderator will be along soon and aprove them for general consumption.

**Woodwould** · 20th January 2011, 05:16 PM

Incidently, I can see the images, so it seems the OP doesn't require moderation to see their own images.

EDIT: My album now shows "6 Moderated Picture(s)".

**Big Shed** · 20th January 2011, 05:25 PM

Having a look at it now guys, I can see the pictures to, both there and in the album.

Not sure what is happening, back soon.

**Big Shed** · 20th January 2011, 06:00 PM

OK, this was indeed caused by some of the recent changes implemented.

Have approved the pictures Woodwould, this has however changed the order of the pictures in your album (I think)

Could you check that everything is OK now please.

**Woodwould** · 20th January 2011, 06:29 PM

Originally Posted by Big Shed

Could you check that everything is OK now please.

The six recently uploaded images do appear in reverse order in my album, but appear in correct order in this post, so I guess all's well.

Are all images to be moderated from now on?

**IanW** · 20th January 2011, 08:16 PM

WW - I see I grossly underestimated your fists! Please remind me to always be very polite, if in your immediate company - a backhander from you is likely to be a very painful experience....

No need to feel embarassed, I am equally so due to my failure to do a job properly. Looking at the pic of the saw (semi-!) enclosed in your hand, I have really underestimated the sweep of the back of the grip that is necessary for economy-sized paws like yours. I see one major difference is that I like the horns to fit snugly, top & bottom (not tightly - just snugly), but you like a much higher upward sweep of the top horn, for the reasons you explained.

Never mind - as I said to you, I was far from confident I had it right, so it looks like a replacement is the only way.....

Cheers,

**RayG** · 20th January 2011, 08:41 PM

Hi WW, I like the way that Apricot handle came up, beautiful colour, and nice clean lines.

Thanks for solving a mystery, I often wondered what was the inspiration for the transition from London Flat pattern handles to Dolphin or Fishtail patterns, now I see (clearly) it's to fit the little finger of people with big hands....

Those S&J handles have been the source of many a blister over the years, my hands start to hurt just looking them. Some industrial designer who never used a saw in his/her life was no doubt very proud of the spacey streamlined look.

Although that said, I have done a bit of a rough study on the way that shape evolved.
Comparative Dating by Style - Saw Discussion Forums

I'm looking forward to the next "real" saw, now that you've got a taste for it....the slope beckons...

Regards
Ray

**Big Shed** · 20th January 2011, 09:01 PM

Originally Posted by Woodwould

The six recently uploaded images do appear in reverse order in my album, but appear in correct order in this post, so I guess all's well.

Are all images to be moderated from now on?

That is not our intention

**Blue-deviled** · 20th January 2011, 10:40 PM

Very nice handle, and a very nice saw too Ian.

WW, if you are going to match the colour of the original Spear & Jackson number, I believe that the Leyland P76 colour, 'Peel Me a Grape' is the one you'd be chasing...

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