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Making a Small Panel Saw #1: The Saw Plate

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Blog entry by Mosquito posted 71 days ago 1971 reads 3 times favorited 24 comments Add to Favorites Watch
no previous part Part 1 of Making a Small Panel Saw series Part 2: Shaping the Tote »

I haven’t got a very large workshop, or bench. I enjoy using hand tools, and often make small rip cuts at my bench in the leg vise. I’ve wanted a small panel saw, in the 16-18” range, for a little while now. I made the decision to try making my own, and a couple of weeks ago I ordered a saw plate and hardware from Two Guys In A Garage Toolworks (www.tgiag.com). I ordered the 6-1/2” x 18” x 0.032” thk small panel/half back saw plate.

My blank saw plate arrived earlier this week, and this is what I’ve done so far…

One thing I didn’t cover too well in the video was how I did the layout.

I found a curve that I liked (roll of tape), and drew the curve at 1 tooth beyond 16”. From there I established the angle of the tote using a Disston No. 7 panel saw template I printed from tgiag.com. The template has a dashed line for where the saw plate goes through the handle. I used where that came out the bottom of the handle, and positioned it to line up with the curve. Then I made marks at 2, 2-1/4, 2-1/2, and 3 inches up the toe of the saw, and started using a straight edge to see what I liked. I settled on 2” for this saw. Using the straight edge to get the top of the handle template at the correct angle to the saw plate, I made my marks for the back of the saw plate, and the top.

Hopefully that wasn’t too confusing… If anyone would like, I could redo the layout phase on a piece of cardboard or paper or something, to go through the steps and take better pictures.

Thanks for checking it out! I hope to have more progress quickly :-)

-- Mos - Twin Cities, MN -- Stanley #45 Evangelist - www.youtube.com/MosquitoMods



24 comments so far

View summerfi's profile

summerfi

937 posts in 286 days


#1 posted 71 days ago

Nice job Mos. Looking forward to the handle.

-- Bob, Missoula, MT -- Of all the tools I own, my favorite is a good sharp pocket knife. - My Dad

View Buckethead's profile

Buckethead

1904 posts in 468 days


#2 posted 71 days ago

Delving into the seedy world of tool making. :-)

Will continue watching. The site to which you linked is pretty cool. It makes me think I could have a go at it.

Do you know what those stair saws are for? Cool looking design, but I’m wondering what they are intended for.

-- Bucket, any person that spends 10k on a bicycle is guaranteed to be a $@I almost started to like you. -bhog

View TerryDowning's profile

TerryDowning

998 posts in 716 days


#3 posted 71 days ago

Nice job there Mos

I see card scrapers and scratch stock in your future as well.

-- - Terry

View terryR's profile

terryR

2970 posts in 907 days


#4 posted 71 days ago

Very nice, Mos. Sounds like an excellent size saw!
Anxious for more. :)

-- tr ...see one, do one, teach one...

View ToddJB's profile

ToddJB

1710 posts in 729 days


#5 posted 71 days ago

Cool, Mos. Looks like there might have almost been enough there to make another saw with the left overs. Wonder if they’d punch both sides?

-- I came - I sawed - I over-built

View JayT's profile

JayT

2089 posts in 810 days


#6 posted 71 days ago

Good blog post, Mos. What thickness plate are you using?

-- "The American Republic will endure until the day Congress discovers that it can bribe the public with the public's money." Alexis de Tocqueville, 1835

View Mosquito's profile

Mosquito

4506 posts in 891 days


#7 posted 71 days ago

Thanks guys.

Buckethead, isn’t my first shop made tool, but it’s the first saw :-)

Terry(D), I didn’t even think of scrapers or scratch stock… had thought about filing my own teeth on the larger piece of scrap as practice, and making a small dovetail saw…

Todd, I bet if you asked they probably would. They’ve got all kinds of different sizes available, and will also do custom sizes as well. I asked about custom sizes, but that was before I knew that they just sent the plate stock and not shaped (which explained why I couldn’t find any saws that looked the same that people created using their plates lol).

Jay, I knew I was forgetting something… .032” thick plate. I bought the Sm Panel / Halfback Saw Plate 6-1/2”x18”x0.032”

-- Mos - Twin Cities, MN -- Stanley #45 Evangelist - www.youtube.com/MosquitoMods

View JayT's profile

JayT

2089 posts in 810 days


#8 posted 71 days ago

Thanks, Mos. I can’t wait until TGIAG has the folded backs available. Oh, the possibilities.

-- "The American Republic will endure until the day Congress discovers that it can bribe the public with the public's money." Alexis de Tocqueville, 1835

View Mosquito's profile

Mosquito

4506 posts in 891 days


#9 posted 71 days ago

Do you know what those stair saws are for? Cool looking design, but I’m wondering what they are intended for.
Sorry, forgot to answer that, I believe they’re intended for dado’s, cutting the side walls of them.

Same here Jay. I know Blackburn tools makes some slotted backs, but I personally like the look of a folded back myself.

-- Mos - Twin Cities, MN -- Stanley #45 Evangelist - www.youtube.com/MosquitoMods

View CL810's profile

CL810

1910 posts in 1587 days


#10 posted 71 days ago

Thanks Mos for sharing your saw build with us.

-- "It's amazing how much can go wrong when you think you know what you're doing."

View Tim's profile

Tim

1173 posts in 560 days


#11 posted 71 days ago

Very nice Mos, that will be a sweet saw. How did you decide on the angle of the plate at the heel end? That angle is what determines the hang angle.

View AnthonyReed's profile

AnthonyReed

4375 posts in 1039 days


#12 posted 71 days ago

Well done Mos. It looks fantastic. Fun stuff to watch too, thanks bud.

-- ~Tony

View Brit's profile

Brit

5107 posts in 1442 days


#13 posted 71 days ago

Nice blog Mos and great to see someone else venturing into the world of video blogging. Looking forward to the next episode.

-- Andy -- Old Chinese proverb say: If you think something can't be done, don't interrupt man who is doing it.

View Buckethead's profile

Buckethead

1904 posts in 468 days


#14 posted 71 days ago

That is what my guess was too, Mos, but it seemed like it might be tough to get a clean dado. The #45 seems like a better option there.

And I fully agree with Brit. I’ve watched you on vid before, and you have that je ne sais quoi. (That’s Swahili for strong pharamones)

-- Bucket, any person that spends 10k on a bicycle is guaranteed to be a $@I almost started to like you. -bhog

#15 posted 71 days ago

hey mos,
that very nicely done, i might do the same thing you did ,
when you sent me that link awhile back i could not stop think about making your on saw,
question what kind of stiffener are you going to use?

-- https://plus.google.com/u/0/b/114897950873317692653/114897950873317692653/posts/p/pub

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