A gift from a French LJ friend.
A strange pack arrives with the postman…
I didn’t order any keyboard…
Was expecting a book…
Ok it was not a book…
What the ‘hack’ is this?
Ahhh yes, it is Sodabowski’s revenge!!!
Some time ago I gave our LJ buddy a challenge – I bought to him a old, really tired and rusty hand plane, because I knew he did not have one, the challenge was that he needed to fix it, and in this way become familiar with the plane, and how to tune a Stanley type hand plane (You can see it here: http://lumberjocks.com/Sodabowski/blog/23584 ).
And so this hacksaw is his favor returned, the boomerang just got me.
But I like a challenge Thomas so I’m in.
Sodabowski have a soft spot for Bakelite and this must be the reason for him to have chosen this saw since the handle is Bakelite – or perhaps it was simply the most rusty thing he could find on the web…
Please notice how elegant the handle is attached, and the wonderful finish on this handle…
I guess I have to let the blade go.
So the show must go on.
After 20 minutes the result is quite impressive.
But still some rust to remove.
After second round the result is impressive.
And some trims.
(It was partly broken, so I cut of the not needed and make it a fixed size frame after).
Then I use a nylon wheel to touch it up.
Left part after the nylon wheel.
Right part after a extra tour with a polish past on a cotton wheel.
Nice heavy metal…
But what about that handle…
First the surfaces need to be flat, they were cut with a handsaw before and looked awful…
So I give them a spin on the disc sander, and as usually sand of some of my skin.
I mark the shape of the frame on to the two side shells.
What is now this?
MaFe goes milling…
Yes for this job I need to learn to use my EMCO UNIMAT 3 for some milling so the saw frame can fit into the handle.
It is great fun, and since I never tried to mill before, I learn a new thing here – yabadabadooo.
This is the result, a fine milled out space for the metal frame.
This setup is better – learning by doing.
Epoxy, two brass alignment pins and clamps – plenty of clamps.
Now the handle comes together.
And when dry I thread a hole in the end of the handle so a threaded brass rod can be fitted in.
The alignment pins are cut of app 2mm from the side, and then I tap then in with a hammer, to make them hold the sides together. (I made the holes taper to secure a firm hold).
Epoxy the threaded rod in, and filling the extra size of the hole with epoxy.
That’s why it’s such a mess.
Epoxy is dry, so time to get that handle back in shape.
First the sides are sanded down on my disc sander.
Then shaping; first with a file and then with different sanding wheels.
And polishing with compounds.
I just discover that the saw is a short version, that will not fit my blades…
Ok I admit this I should have checked first!
But lucky me – It is just possible.
So drilling a maximum hole and hammer in a pin.
Yes now my workshop is back to being not a wood shop again…
Silver solder, and a burner, in this way it should become strong enough.
(I guess I would be lost in the work shop of Schwarz, I need way more tools than he describe in that book, and he don’t even have a hacksaw – lol).
Pin a silver.
And another pin.
I did it Sodabowski !!!
I hope you are pleased, I spend about eight hours on this guy, choose to keep the handle out of respect for you, and the shape of the handle out of respect for the guy that made it, the shine and the polish is for me.
I have no doubt what will be my favorite hacksaw now.
Thank you for the gift.
Now I will sit back in the chair and wait to see your post on your hand plane, I think I have earned it.
Hope this blog can bring some inspiration to others, that it can show that what might seem as trash to some can be a jewel to others.
-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.