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Making a Small Panel Saw #1: The Saw Plate

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Blog entry by Mosquito posted 05-15-2014 05:43 PM 2412 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 (online now)

summerfi

1452 posts in 431 days


#1 posted 05-15-2014 06:00 PM

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

1935 posts in 613 days


#2 posted 05-15-2014 06:18 PM

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

1024 posts in 861 days


#3 posted 05-15-2014 06:20 PM

Nice job there Mos

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

-- - Terry

View terryR's profile

terryR

3481 posts in 1052 days


#4 posted 05-15-2014 06:26 PM

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

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

View ToddJB's profile (online now)

ToddJB

2986 posts in 874 days


#5 posted 05-15-2014 06:28 PM

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

2602 posts in 955 days


#6 posted 05-15-2014 06:31 PM

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

5170 posts in 1036 days


#7 posted 05-15-2014 06:40 PM

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

2602 posts in 955 days


#8 posted 05-15-2014 06:45 PM

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

5170 posts in 1036 days


#9 posted 05-15-2014 06:49 PM

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

2382 posts in 1732 days


#10 posted 05-15-2014 07:05 PM

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

1382 posts in 705 days


#11 posted 05-15-2014 07:12 PM

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 (online now)

AnthonyReed

5068 posts in 1184 days


#12 posted 05-15-2014 07:15 PM

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

-- ~Tony

View Brit's profile

Brit

5300 posts in 1587 days


#13 posted 05-15-2014 08:35 PM

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

1935 posts in 613 days


#14 posted 05-15-2014 09:02 PM

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

View August McCormick Lehman III's profile

August McCormick Lehman III

1271 posts in 234 days


#15 posted 05-15-2014 09:16 PM

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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