Well, I am going to build another bow saw. I don’t need another one but this one will be more special to me. Last time, I used the hardware from Grammercy. This time, I made my own hardware.
This is what the Grammercy hardware looks like:
I picked up a metal lathe a while back and finally took it out of the packing crate. The lathe is a little 7×10 from Harbor Freight. I decided that my first project would be to make another set of pins for a bow saw. It is pretty simple but, hey, you have to start somewhere.
The first attempt was with some mystery aluminum alloy from Home Depot. Total disaster. As I was turning the second end, the metal failed from me pushing too hard. Basically, it was mush. That’s ok. I didn’t expect it to be perfect the first time around.
I went by to get some lumber for another project and thought I would try again. I picked up a piece of 1/2 in. hot rolled steel rod to try out cutting something else. This was a lot stronger but it is a lot harder to work with than the aluminum. Then it came time to slot the blade holder. My hacksaw was not up to it and I ended up cutting the slot out crooked and messed up the blank.
Third time was the charm. I had done some dumpster diving and pulled some pieces of 6061 Aluminum from the scrap bin at work. A world of difference. It cut really well and was strong enough to support itself without bending. I left the handle end a bit longer than the Grammercy set and cut the slot for the blade with my multi-tool and cleaned up with files.
I rank it pretty high on the fun scale but unless you really want to practice on a metal lathe, I really suggest buying the hardware if you are going to build one.
-- Woodworking shouldn't cost a fortune: http://lowbudgetwoodworker.blogspot.com/