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18th August 2019, 09:17 PM #1
The troubles of the back saw slot.
The troubles of the back saw slot.
One of the most difficult areas I find, an I don’t think I stand alone hear.
Is making a neat tidy mortise for the back to slide neatly ,but tightly into a Saw handle.
It’s a tricky one, your working on material generally any wear between 20/23 mm thick.
You need the mortise to be dead centre in your Saw handle and parallel to the sides of the handle,it needs to be approximately 30 mm long 10/15 mm deep.
(All above measures pulled from thin air lol)
This is traditional done by just either sawing your walls as much as possible before hitting the back of the slot, then chiseling out the waste with a small chisel.
Problem I find is ,making sure the top of mortise the area were the spline sits proud or flush ,depending on how your making your saw ,can look average if it’s a bit crumbly or your not exactly square.
So ,this has been something that has caused me many minutes of lost sleep.
An till now.
I present too you my fine friends an enemies.
The saw handle holding vice thingy Mk1(Don’t buy Mk 1 ever there always WIP)
The vice is your standard couple of bits of 32 mm MDF made into a couple of large L sections, but the critical point on these is ,the tops must be square and parallel till each other.
Now , I think I’ve hit the gold mark,
While spending an evening window shopping on the net one night, I finally came across a long metal end milling cutter
6 mm by 100 mm long .
And 6 mm is a fraction narrower then a 1/4 inch(0.23)
So ,if I fitted the milling cutter into my trim router(it snugged up nice an tight with the collet)an made a simple centring attachment
I could route out the slot [emoji41][emoji41][emoji41].
Now ,the reason I needed a long bit was ,due to the distance from the top of the vice jaws to the bottom of the mortace.
Remembering on most traditional back saws ,
there is a funny hook thingy above your mortise slot[emoji85] (sorry I should have measured that [emoji849])
So with no further to do I asked Sal if she would like to be the first person to use my new crazy gizmo, I took a few dozen steps back for safety,
No ok I did it, an the first try was dismal it had a step on the side,
So I chucked the first bit of timber in the bin an tried again,yes success an as they say a pic is worth a thousand camels[emoji849].
An just a few more pics for prof of concept an using my other soon to be finished saw and it’s back,
My apologies that I should have taken some better shots showing the router in place extra.[emoji85][emoji849]
So I think I may have over come, one of my own little personal problems in live, I’m quite chuffed with this.
Cheers Matt,
I may paint it RED next weekend so that it works faster.
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18th August 2019, 10:50 PM #2
That’s excellent Matt. I’ve only made two handles, the first of which was destroyed doing the back cutout, so read this with great interest.
In attempting to salvage my first attempt, I tried using the router table, but that really chewed things up. I think your use of a trim router is much smarter, as you will be able to see what you’re doing, and hopefully have a little more control.
I will be interested to see others’ responses as to how they tackle this area.
Kind regards,
Lance
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19th August 2019, 09:24 AM #3
Lance,
The trick was finding the end mil cutter.
All the 1/4 inch router bits I found were to short.
The mill cutter being 100 mm long by 6 mm.
Was perfect,
It had the required reach and I think from memory was under $15 sent from China.
I forgot to mention I did ruff out some of the waste first with 3 mm drill bit, to take the strain of the cutter a bit.
Cheers Matt,
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24th August 2019, 05:40 PM #4
Matt
I have only just spotted this thread. Now I know what you have been up to!
Most interesting. Am I right in thinking that the milling cutter will only really cut at the bottom of the cut? If that is the case I imagine you had to drill out the majority of the waste first. Actually, drilling out the waste is the first improvement over just using the chisel once the saw can no longer get in because of the angle.
I must look into this.
Looks to me like some backsaw activity coming up.
Regards
PaulBushmiller;
"Power tends to corrupt. Absolute power corrupts, absolutely!"
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24th August 2019, 07:43 PM #5
Paul
Do I have no privacy!!
No I’m afraid the milling cutter cuts both side walls of the mortise and the bottom.
But that is a nice thing.
But the reason I pre drilled the mortise is to basically take the strain of the cutter.
But do bear in mind this is first time I’ve ever used a milling cutter[emoji849].
Yes I “may” make another saw or two in the future [emoji85][emoji85].
Cheers Matt,
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