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Blog series by Ron Aylor updated 04-15-2018 11:28 PM 4 parts 6333 reads 57 comments total

Part 1: The Want

04-13-2018 03:01 PM by Ron Aylor | 15 comments »

The Want - For years I have been resawing stock with a rip cut handsaw … both hardwoods …  … and softwoods.  Although this has proven successful, I have always wanted to add a frame saw to my arsenal, for this purpose. I have hesitated, up to now, for the sole reason of blade attachment. I have seen many different methods using tubular steel with inset bolts for blade tension, but I do not have the capacity to work with metal.  I recently obtained a copy of TOOLS: Working Wood in Eight...

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Part 2: Handles

04-13-2018 06:59 PM by Ron Aylor | 10 comments »

Handles - Having cut out the first handle with a coping saw, I used files and rasps to further define the shape.                 I then transferred the shape to another cherry board and started all over again.  I think these two handles are pretty close …  ... especially when viewed at three feet apart … LOL!  Overall this saw will be approximately 40” long and 20” wide. Next I need to cut the 3/4” x 1” side rails, and joint them, via through mortise and tenon, to the handles before tac...

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Part 3: Cart Before the Horse

04-14-2018 08:09 PM by Ron Aylor | 18 comments »

Cart Before the Horse –  I know I said I was going to attach the side rails next, but as I was ripping these parts …  … it dawned on me that I didn’t know how long they needed to be. I wouldn’t know the length until the blade attachment pieces were in place. So, once I laid out their shape on a cherry board, I drilled holes for the blade pins …                 … cut mortises for the handles to pass through …  … making sure everything stayed square …  … and tight.            ...

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Part 4: Side Rails and a Test Drive

04-15-2018 11:28 PM by Ron Aylor | 14 comments »

Side Rails and a Test Drive –  After reorienting the horse and the cart, I used my tenoning clamp & chairmarker's tenon saw ...   … to create a tenon at one end of each of the two 3/4” x 1” cherry side rails.   I then cut 3/8” x 3/4” x 1-3/8” through mortises in the handles …  ... to accept the side rails.                 After a quick check for squareness …  I assembled one end of the saw and attached the blade …  … It was then that I was able to determine the len...

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