Making a Small Panel Saw #2: Shaping the Tote

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Blog entry by Mosquito posted 06-16-2014 06:51 PM 2253 reads 0 times favorited 13 comments Add to Favorites Watch
« Part 1: The Saw Plate Part 2 of Making a Small Panel Saw series Part 3: Drilling the Tote, and Applying Finish »

Here’s part 2 of the video series where I make the tote for my panel saw. The tools I used for shaping it were just a standard hardware store “wood rasp”, a 4-in-1 rasp (also cheap hardware store variety), a couple of hardware store hand files, and a Gramercy Handle Makers rasp.

I used a D-7 panel saw template from

-- Mos - Twin Cities, MN - -

13 comments so far

View terryR's profile


7394 posts in 2482 days

#1 posted 06-16-2014 07:18 PM

Looks great, Mos!
D-7 tote is one of my favs!

Thanks for sharing parts 1&2…I’m just a few steps behind you. LOL!

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

View ToddJB's profile


8271 posts in 2304 days

#2 posted 06-16-2014 07:33 PM


First, your beard looks great.

Second, I really REALLY like the style of editing where you speed it up, but leave the actual audio – it’s a cool effect.

Third, post drills, it appears when you lower the drill there is a good bit of run out. Is this typical of post drills? It wouldn’t be a big deal for wood working, but might be a deal breaker for metal working.

Forth, thanks for sharing the step by step. Great tutorial.

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

View TerryDowning's profile


1102 posts in 2291 days

#3 posted 06-16-2014 08:16 PM

Nicely done Mos!

-- - Terry

View Mosquito's profile


9494 posts in 2466 days

#4 posted 06-16-2014 08:25 PM

Terry the D-7 is also my favorite tote, hence why I used it :-)


1.) Thanks, been practicing for about 8 years now lol
2.) Thanks, I rather liked it too, for that kind of stuff anyway. When cutting metal, some sort of music blip is nicer I think
3.) It does have a little bit of run out, and I’m guessing different post drills will have different amounts of run out. I imagine it’d have to do with the tolerances of the manufacturer of the post drill.
4.) No problem, I enjoy doing it, but sometimes I get too “In the moment” and stop shooting video, or when my shop time gets sporadic, I don’t always do the video like I should as I just want to get it done :-/


Thanks Terry (D)

-- Mos - Twin Cities, MN - -

View Brit's profile


7522 posts in 3016 days

#5 posted 06-16-2014 09:40 PM

Thanks Mos, I enjoyed that tutorial and nice to see the post drill do its thing. Do you know who the manufacturer was and what model drill it is?

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

View Mosquito's profile


9494 posts in 2466 days

#6 posted 06-16-2014 10:03 PM

Thanks Brit. Model is No. 00 816, manufacturer I’m not really sure, I haven’t been able to dig much up on it, just a “worth point” page for an e-Bay listing that didn’t know what it was either. It seems to be most closely resembling Champion Blower & Forge, but there’s no manufacturer on it anywhere, just 3 spots on one side that say No., 00, and 816 on them

-- Mos - Twin Cities, MN - -

View 7Footer's profile


2569 posts in 2122 days

#7 posted 06-16-2014 10:41 PM

Thanks Mos, great vid. It will be really helpful for the upcoming saw swap too as well.


View Tim's profile


3812 posts in 2135 days

#8 posted 06-16-2014 11:34 PM

Awesome video, Mos. Thanks for sharing the detail. I like the sped up parts too, especially since you just speed the repetitive part and don’t skip any steps.

View Mosquito's profile


9494 posts in 2466 days

#9 posted 06-17-2014 02:22 PM

Thanks 7’, I had started it well before I knew the next swap was going to be a saw swap, maybe I would have spent more time and been more meticulous if I did lol

Thanks Tim, I didn’t really like most of the videos that just went “You cut out the tote” [scene change] “Ok, here’s the tote done”. In the 3rd part, I cut out a lot more of the repetitive parts after a few seconds of starting it, as it’ll already be a little longer than these two; even more so if I don’t.

-- Mos - Twin Cities, MN - -

View helluvawreck's profile


32087 posts in 3040 days

#10 posted 06-17-2014 02:38 PM

You’ll always cherish the saw and it will make a great addition to your shop. Nice work.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Mosquito's profile


9494 posts in 2466 days

#11 posted 06-17-2014 03:23 PM

Thanks Charles. This was the “trial” saw, as I fancied the idea of some day having a full saw till of all saws I made. It’s gone well enough, so I may just end up with that some day. Parts/kits might make for good birthday/Christmas present ideas, since I never have any otherwise lol

-- Mos - Twin Cities, MN - -

View AnthonyReed's profile


10040 posts in 2614 days

#12 posted 06-17-2014 07:59 PM

Extremely well done Mos. Content, fit and finish are top notch. As is your craftsmanship. Heavy on hand tools puts it over the top. I’m really enjoying following along.


-- ~Tony

View Mosquito's profile


9494 posts in 2466 days

#13 posted 06-17-2014 08:12 PM

Thanks Tony. Come to think of it, on this one (the tote, obviously used rotary tool on the plate) I didn’t use any power tools for it. I did on my practice (first) tote to drill the holes, but that was before I had mounted the post drill. Really starting to like that purchase more and more lately

-- Mos - Twin Cities, MN - -

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