Bad Axe Saw manufacturing

**hiroller** · 14th February 2020, 10:06 AM

Bad Axe have posted on instagram a little about their saw manufacturing process that is of interest.
They have certainly scaled to beyond the individually crafted saw methods used by some of the smaller makers that have come and gone.
BadAxeToolWorks on Instagram: “A glimpse into what goes into a Bad Axe D8: While handles and fasteners are beautiful, the reality is that it's the quality of the metal…”

Here's a glimpse into how Bad Axe makes that happen:
- We begin with a 2000-lb roll of annealed 1095 spring steel and have it custom heat-treated, tempered and hardened by specialists who have worked spring steel their entire careers.
- A Bad Axe D8 can accurately claim a Rockwell hardness of 51-52-approaching the limit of how hard you can make spring steel to retain an edge without having teeth snap off when setting the toothline.
- We then had the metal sheared to length/width and laid flat in multi-plate sections to avoid what's known as 'coil set,' -a phenomenon in the metal industry in which processed metal is rolled into a huge coil, imparting curvature to the spring steel which we have managed to avoid altogether.
- The next stage is waterjetting the plate to form and pitch. Unlike machining, stamping or laser-cutting, a waterjet cutting process avoids disrupting the temper or stiffness of the plate and imparts zero stress to the metal, which again can affect its flatness and ability to spring back to true: you want sawplate metal as stiff as possible when cutting through wood fiber, so it won't buckle and kink in the cut.
- Then comes a delicate grinding operation that removes metal on both sides of the plate to mitigate the need for heavy set in the toothline--you want the toothline to cut cleanly through the kerf and the rest of the saw to get out of the way. The trick with grinding is to keep the metal cool during the grinding process, again to avoid disrupting the temper attained during the heat-treat process.
- The final step is lasering-etching our logo onto the plate, before the rest of the work gets underway: setting the teeth, sharpening to joint, then mounting the handle and fasteners onto the saw.

**Bushmiller** · 15th February 2020, 11:25 PM

Gavin

Most interesing that they cut the teeth with a laser. Ole Henry would have been straight around to the patent office! Thanks for the info.

Regards
Paul

**NCArcher** · 16th February 2020, 07:54 AM

Originally Posted by Bushmiller

GavinOl

Most interesing that they cut the teeth with a laser.

Regards
Paul

Cut with a water jet Paul. Laser is to etch the logo.

**Bushmiller** · 16th February 2020, 09:00 AM

Thanks Tony

I knew that! But I crossed my lasers and my water jets

.

The reason I had mentioned it was I didn't realise a water jet could cut so small kerf. Some years back a group buy of chisels had the blades cut by water jet from the large steel plate. I was trying to visualise a jet of water cutting teeth at 12ppi.

Regards
Paul

**Simplicity** · 16th February 2020, 09:20 AM

Originally Posted by Bushmiller

Thanks Tony

I knew that! But I crossed my lasers and my water jets

.

The reason I had mentioned it was I didn't realise a water jet could cut so small kerf. Some years back a group buy of chisels had the blades cut by water jet from the large steel plate. I was trying to visualise a jet of water cutting teeth at 12ppi.

Regards
Paul

Here you go Paul,
This would be perfect for all those saws that need to be re toothed.

“Accuracy. Flow waterjets can make parts to very tight tolerances, some systems can create parts with a tolerance as close as 0.001" (0.025 mm). For waterjet cutting, typical part tolerances range from between 0.003" and 0.005" of an inch.”

Pinched this from web thingy

Cheers Matt

**Bushmiller** · 16th February 2020, 12:06 PM

Originally Posted by Simplicity

Here you go Paul,
This would be perfect for all those saws that need to be re toothed.

“Accuracy. Flow waterjets can make parts to very tight tolerances, some systems can create parts with a tolerance as close as 0.001" (0.025 mm). For waterjet cutting, typical part tolerances range from between 0.003" and 0.005" of an inch.”

Pinched this from web thingy

Cheers Matt

Wow Matt.

You are now talking to a convert. I will check out the local hardware to see what they have.

Regards
Paul

**Simplicity** · 16th February 2020, 12:44 PM

Originally Posted by Bushmiller

Wow Matt.

You are now talking to a convert. I will check out the local hardware to see what they have.

Regards
Paul

An please report back with your findings.[emoji6]

Now if we can get a suitable amount of 1095 spring steel,
Enough people(Addicts) wanting panel saws,
We could have them all toothed and cut out at once?
Immmmmm.!!!!

Cheers Matt.

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