A Few Handmade Saws

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Project by ErikF posted 04-21-2014 09:09 PM 3439 views 10 times favorited 36 comments Add to Favorites Watch

I should have never bought that old Disston saw from a garage sale. It got me started down the path of handsaws and now I can’t stop building them. I really enjoy the combination of woodwork and metalwork that goes into each of the saws. Also, I can use wood that I never dreamed of buying because a BF of a nice exotic 4/4 goes a good distance when making saw totes.

-- Power to the people.

36 comments so far

View woodchuckerNJ's profile


1140 posts in 1054 days

#1 posted 04-21-2014 09:18 PM

Some nice stuff there.
Are you cutting the teeth or just using old plates?

Carbon Fiber???? I think I like the brass back better.

Those closed totes might hold 3 of my fingers :-(
oh, that’s all that normally go there …. doh

-- Jeff NJ

View waho6o9's profile (online now)


7119 posts in 1996 days

#2 posted 04-21-2014 10:13 PM

Great work Erik.

View mafe's profile


11061 posts in 2509 days

#3 posted 04-21-2014 10:31 PM

Super cool saws, I love the idea of carbon fiber s back, but perhaps also the handle should go into space then.
Lovely work.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View MactheKnife's profile


81 posts in 1288 days

#4 posted 04-21-2014 10:40 PM

Nice saws. I second Woodchuck’s enquiriy, are you making the blades from scratch?

View ErikF's profile


498 posts in 1663 days

#5 posted 04-21-2014 10:52 PM

I cut the blades from 1095 spring steel sheets and do all the shaping and toothing from there. I also make the brass bolts and split nuts. Up until this morning I have had to file each tooth by hand, start to finish. BUT this morning I finished my most recent project: a fly press fitted with a homemade punch, die, and jig used for the initial toothing. I was able to tooth a 18” saw in 7 minutes this morning instead of 30 to 45 minutes. Here she is…

-- Power to the people.

View Don W's profile

Don W

17875 posts in 1987 days

#6 posted 04-21-2014 11:10 PM

Nice craftsmanship.

-- Master hand plane hoarder. -

View cdaulton's profile


25 posts in 1888 days

#7 posted 04-22-2014 12:23 AM

How to you cut the slots in the brass for the backs?

View DocSavage45's profile


7648 posts in 2262 days

#8 posted 04-22-2014 12:36 AM


I am in awe of your skill and talent. Have you considered going into business? You could give Lie Nielsen some excellent competition.

-- Cau Haus Designs, Thomas J. Tieffenbacher

View woodchuckerNJ's profile


1140 posts in 1054 days

#9 posted 04-22-2014 12:44 AM

Eric I am familiar with an arbor press (which this is not)
and a punch press machine (with motor) again this is not.

How does a fly press work? Just spin the wheel (fly weights)?

Cool that you are doing the plates completely.

Edit: found a youtube video on the fly press.. never saw one b4.. good to know.

-- Jeff NJ

View ErikF's profile


498 posts in 1663 days

#10 posted 04-22-2014 01:03 AM

cdaulton- I use a vertical mill with a slitting saw attachment to slot the brass. It is doable with a drill press but there isn’t as much control.

Doc- Thanks, I have been selling the saws as I go along in order to pay for more saw supplies. I would like to get more serious with it when I get out of the military.

-- Power to the people.

View Skelatile's profile


70 posts in 2216 days

#11 posted 04-22-2014 02:20 AM

Im really intrigued by the carbon fiber idea! how does it compare to the traditional brass?

View woodify's profile


130 posts in 1492 days

#12 posted 04-22-2014 02:21 AM

View ErikF's profile


498 posts in 1663 days

#13 posted 04-22-2014 02:48 AM

The carbon fiber makes for a very light saw. My go-to dovetail saw has a carbon fiber spine, the feedback is great and I haven’t noticed the lack of weight slowing the cut. The drawback is that it is a lot more expensive than brass and destroys my HSS cutters. One slotted back and the cutter is toast.

-- Power to the people.

View summerfi's profile


3261 posts in 1107 days

#14 posted 04-22-2014 03:58 AM

Great job Erik. You’re producing some fine saws, and the development of technique you’ve put into it is impressive.

-- Bob, Missoula, MT -- Rocky Mountain Saw Works

View ronstar's profile


282 posts in 3130 days

#15 posted 04-22-2014 11:17 AM

Very nice saws!

-- Ron, Northern Illinois

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