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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 3447 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 - http://www.youtube.com/MosquitoMods - http://www.TheModsquito.com



24 comments so far

View summerfi's profile

summerfi

3143 posts in 960 days


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

Nice job Mos. Looking forward to the handle.

-- Bob, Missoula, MT -- Rocky Mountain Saw Works http://www.rmsaws.com/p/about-us.html

View Buckethead's profile

Buckethead

3140 posts in 1142 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.

-- Support woodworking hand models. Buy me a sawstop.

View TerryDowning's profile

TerryDowning

1049 posts in 1390 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

5788 posts in 1581 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

ToddJB

6060 posts in 1403 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

4316 posts in 1484 days


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

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

-- "Good judgement is the result of experience. A lot of experience is the result of poor judgement."

View Mosquito's profile

Mosquito

7479 posts in 1565 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 - http://www.youtube.com/MosquitoMods - http://www.TheModsquito.com

View JayT's profile

JayT

4316 posts in 1484 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.

-- "Good judgement is the result of experience. A lot of experience is the result of poor judgement."

View Mosquito's profile

Mosquito

7479 posts in 1565 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 - http://www.youtube.com/MosquitoMods - http://www.TheModsquito.com

View CL810's profile

CL810

3273 posts in 2261 days


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

Thanks Mos for sharing your saw build with us.

-- "The only limits to our realization of tomorrow will be our doubts of today." - FDR

View Tim's profile

Tim

2848 posts in 1234 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

AnthonyReed

7928 posts in 1713 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

6152 posts in 2116 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

3140 posts in 1142 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)

-- Support woodworking hand models. Buy me a sawstop.

View August McCormick Lehman III's profile

August McCormick Lehman III

1744 posts in 763 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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