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  1. 24th February 2009, 07:48 AM #1
    RayG's Avatar
    RayG
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    Default Sash Tenon Saw (plus) How to make a Saw Handle

    I was making a tenon saw with a Huon Pine handle, and although it looked ok, the front split, when I was finishing the fitting and so I had to make a new handle.

    This time from walnut, so I though it might be a good time to document the handle making process. It ended up too big for a forum post, so I have made it into a downloadable pdf. see below.

    Here are some pics. This is the Huon Pine one that failed.



    The new handle from walnut



    And the rest of it,



    The pdf file is downloadable from here http://www.backsaw.net/SawHandles101.pdf

    The saw is 14" long 20 thou plate, and will be filed 12PPI rip, when I get around to it..

    Regards
    Ray

    PS... The BobNBunnies D9 is not far away..
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  3. 24th February 2009, 10:38 AM #2
    tomnewby
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    Gee I love looking at your saws....
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  4. 24th February 2009, 10:46 AM #3
    Wongdai
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    Thats great. I have a couple of Distons I was thinking of making new handles for, and this has convinced me.
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  5. 24th February 2009, 11:29 AM #4
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    Another 'ripper'!
    .
    I know you believe you understand what you think I wrote, but I'm not sure you realize that what you just read is not what I meant.

    Regards, Woodwould.
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  6. 24th February 2009, 11:52 AM #5
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    Nice saw and handle Ray. Also that PDF is very informative - greenie on the way.
    Cheers.

    Vernon.
    __________________________________________________
    Bite off more than you can chew and then chew like crazy.
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  7. 24th February 2009, 02:52 PM #6
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    Slow6 is offline Luban White
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    Really nice Ray lovely form to that handle.

    Such a shame about the huon. I would have liked to seen how it held up to a little abuse.
    Best regards, Luban
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  8. 24th February 2009, 03:24 PM #7
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    Lovely work once again Ray. Thanks
    Kevin
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  9. 24th February 2009, 05:25 PM #8
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    Quote Originally Posted by Slow6 View Post
    Such a shame about the huon. I would have liked to seen how it held up to a little abuse.
    I abused it a little after it split, I don't think it was listening however..

    Even so it's hard to give up entirely on the Huon Pine as handle material... It has a nice creamy sort of texture that I like. Beautifull stuff to work as well.

    I am thinking that I might fill the grain in the vulnerable areas with CA glue before finishing.

    Regards
    Ray
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  10. 24th February 2009, 09:24 PM #9
    Heavansabove
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    Great work Ray. I have been given a new Shark hardpoint saw 13" - absolutely unusable, which is why it was given to me. So I guillotined off the teeth (had access to a Supershear), and will cut new teeth and make a new handle of course. Combined with the brass back order, might even be a useful saw.

    Thanks for the PDF. I have used files after the rasps when reworking factory handles, reduces the need for sanding (for which I use cut up sanding belts mostly).

    Regards
    Peter
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  11. 24th February 2009, 09:48 PM #10
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    mmmmm nice shiny saw with tasty handle mmmmm. Shame about the one hewn from Huon . Later on in the year we'll be making a saw at school and I just might copy your handle. Cheers!
    Sharp is Best!
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  12. 25th February 2009, 09:14 AM #11
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    Claw Hama
    Claw Hama is offline Heavy Machinery
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    Sweet, very sweet Ray and nice job of the instruction pdf.
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    www.solidwoodfurniture.com.au

    A good edge takes a little sweat!!
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  13. 25th February 2009, 10:08 PM #12
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    Love the London pattern handle .It's a gorgeous looking saw Ray.


    Kev.
    "Outside of a dog a book is man's best friend ,inside a dog it's too dark to read"
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  14. 25th February 2009, 10:26 PM #13
    Pusser
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    Lovely work and a great pdf
    I never make mistakes, I thought I did once but I was mistaken

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  15. 26th February 2009, 12:11 AM #14
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    Thanks all for the comments, but somtimes I just can't leave well enough alone, after looking at the handle for a while, I decided that I would prefer that crisp look with the flat sides.

    So I pulled it apart and flattened the sides to create that shadow line look....







    The pdf has been updated, and the web page is now at
    http://www.backsaw.net/index.php?opt...=58&Itemid=102

    Remind me to leave things alone in future...

    Regards
    Ray
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  16. 26th February 2009, 11:11 PM #15
    BobL
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    Very nice, how does it cut?
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