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How to Make a Pad Saw (for cutting into a board face)

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Blog entry by WoodAndShop posted 05-10-2014 01:36 PM 1753 reads 0 times favorited 6 comments Add to Favorites Watch

By Joshua Farnsworth (Writer at WoodAndShop.com)

In the above Video I show how I made a simple (and cheap) “Pad Saw”, sometimes referred to as a “Keyhole Saw”. I was building the simple, yet amazing Roubo Bookstand featured by Roy Underhill in this episode of The Woodwright’s Shop (click here for the video episode).

But I didn’t own a pad saw, and I also found some missing details in Roy’s tutorial. So I decided to make my own pad saw with a scrap of poplar (you can use any wood) and an old hacksaw blade I had laying around. Cost to me? Nil.

I drilled a 1/16th inch pilot into the bookstand board (see my above video) and then attempted to follow Roy Underhill’s advice for scraping the hole out. But after two hours, I was just frustrated; Getting nowhere. I finally tried securing the blade a bit more with a screw (used a metalworking drill bit like these) and that helped enormously.

But the work was still painfully slow. So I tried standing the bookstand board upright in my workbench vice. That did the trick! The last two slots were cut in 5-10 minutes, compared with 2 hours for the first two slots.
I hope this helped!
Do you have any creative homemade tool ideas? Please share them in the comment section below.

-- Joshua Farnsworth - Free Traditional Hand Tool Woodworking Tutorials: http://WoodAndShop.com



6 comments so far

View kiefer's profile

kiefer

3186 posts in 1363 days


#1 posted 05-10-2014 06:01 PM

Here is a little saw I made some time ago that uses a coping saw blade section with the teeth directed to cut on the pull stroke .
Have used it here and there and it sure handy sometimes when nothing else works.


-- Kiefer 松

View WoodAndShop's profile

WoodAndShop

141 posts in 205 days


#2 posted 05-10-2014 06:59 PM

Hey Kiefer, that’s a great little saw!

-- Joshua Farnsworth - Free Traditional Hand Tool Woodworking Tutorials: http://WoodAndShop.com

View Paul Maurer's profile

Paul Maurer

141 posts in 251 days


#3 posted 05-10-2014 07:53 PM

Improvise, adapt, overcome.
Many inspired from fellow LJ’s

Also, one Roy wanted me to make- “I want you to make this lathe.” (The Woodwright’s Guide page 166)

-- Psalm 62: 11 Once God has spoken; twice have I heard this: that power belongs to God, 12 and steadfast love belongs to you, O Lord. For you repay to all according to their work

View WoodAndShop's profile

WoodAndShop

141 posts in 205 days


#4 posted 05-11-2014 12:15 AM

Nice TooliganGalloot! Love the spring pole lathe! Did you take a class from Roy?

-- Joshua Farnsworth - Free Traditional Hand Tool Woodworking Tutorials: http://WoodAndShop.com

View Paul Maurer's profile

Paul Maurer

141 posts in 251 days


#5 posted 05-11-2014 03:10 AM

No, I did not take the class, I just read the book. The book was much more affordable and did not require travel and lodging expenses.

-- Psalm 62: 11 Once God has spoken; twice have I heard this: that power belongs to God, 12 and steadfast love belongs to you, O Lord. For you repay to all according to their work

View NormG's profile

NormG

4270 posts in 1700 days


#6 posted 05-11-2014 04:14 PM

Great idea for the pad saw materials

-- Norman

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