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Dovetail Saw from a Gents Saw

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Project by AgentTwitch posted 04-07-2016 11:30 AM 1819 views 14 times favorited 26 comments Add to Favorites Watch

After seeing some amazing transformations of inexpensive gents saws to high quality western dovetail saws here on lumberjocks, I decided to give it a try. After settling on the Gramercy dovetail saw design, I bought an inexpensive Crown 10” Gents saw with 16 PPI and a steel back, two brass 7/16” saw nuts and some Blue Magic metal polish for the saw spine and plate.

I removed the old handle (saving it for a file holder) and used acetone to clean off the lacquer. Sanded with 220, 320 and then scotch bright before applying metal polish. It is like a mirror in person. I also cut the saw plate down so it was tapered about 3/8” from toe to heel.

I used an inexpensive carbide tipped “V” router bit at the drill press to easily bore precise holes into the saw plate. Way easier and faster than punching a hole or using HSS/TiN/Cobalt bits in my experience.

Cut a .020 inch kerf into the saw handle using a slitting saw at the router table

The shaping was done with a round over bit and rasps.

The finish is shellac and Minwax Antique Oil (I really like this stuff!)

If you want to make a saw, but dont want to do it entirely from scratch or buy an expensive kit, this is a great way to get started. The saw is light weight, and the teeth on the saw plate are already set and sharp (though you may want to sharpen it before use anyway).

-- Regards, Norm





26 comments so far

View Smitty_Cabinetshop's profile

Smitty_Cabinetshop

13738 posts in 2084 days


#1 posted 04-07-2016 11:55 AM

Very nice!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View mounttod's profile

mounttod

30 posts in 437 days


#2 posted 04-07-2016 12:27 PM

I would have thought this was any number of the super expensive brand saws. Great job!

View JayT's profile

JayT

4785 posts in 1677 days


#3 posted 04-07-2016 12:33 PM

Well done, Norm. Love the grain in that handle.

-- "Good judgement is the result of experience. A lot of experience is the result of poor judgement."

View AgentTwitch's profile

AgentTwitch

528 posts in 2962 days


#4 posted 04-07-2016 12:52 PM

Thanks for the kind words. JayT, your re-handle saw project made me want to give this a try. Thanks for the inspiration!

-- Regards, Norm

View WirelessWoodworker's profile

WirelessWoodworker

54 posts in 722 days


#5 posted 04-07-2016 01:12 PM

This is fantastic, thanks for sharing Norm!

-- Tim, Delaware, http://www.thewirelesswoodworker.com

View Julian's profile

Julian

1037 posts in 2156 days


#6 posted 04-07-2016 01:48 PM

Good tip on using a router bit to make the screw holes. I need to do this one day.

-- Julian

View shipwright's profile

shipwright

7174 posts in 2263 days


#7 posted 04-07-2016 01:53 PM

Very nice work Norm.
It looks elegant and efficient. It makes me want to make one but I really like Japanese saws for my DTs. Maybe there will be another swap and I can make one for someone else…
Anyway, really nice piece of work!

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

View AgentTwitch's profile

AgentTwitch

528 posts in 2962 days


#8 posted 04-07-2016 02:39 PM

Paul, please feel free to give it a try and send it my way :-)

-- Regards, Norm

View a1Jim's profile

a1Jim

115202 posts in 3043 days


#9 posted 04-07-2016 02:45 PM

Looks great.
I was wondering where do you buy your slitting saws at?

-- http://artisticwoodstudio.com Custom furniture

View AgentTwitch's profile

AgentTwitch

528 posts in 2962 days


#10 posted 04-07-2016 03:10 PM

Jim, I think I got the slitting saw and 1/2” arbor from MSC Direct. I like that I can use it in my drill press and lathe. I have a .032 slitting saw as well for some other saw projects in the future.

-- Regards, Norm

View a1Jim's profile

a1Jim

115202 posts in 3043 days


#11 posted 04-07-2016 03:20 PM

Thanks Norm ,slitting saws are tools I don’t have any experience with,I’m a bit surprised they can be used in a router table.

-- http://artisticwoodstudio.com Custom furniture

View summerfi's profile

summerfi

3315 posts in 1153 days


#12 posted 04-07-2016 03:27 PM

Fantastic job Norm. It looks great!

-- Bob, Missoula, MT -- Rocky Mountain Saw Works http://www.rmsaws.com/p/about-us.html

View JayT's profile

JayT

4785 posts in 1677 days


#13 posted 04-07-2016 03:29 PM


Thanks for the kind words. JayT, your re-handle saw project made me want to give this a try. Thanks for the inspiration!

- AgentTwitch

You’re welcome, I think. You sure took the concept (that I “stole” from Airframer, anyways) to a much higher level.

-- "Good judgement is the result of experience. A lot of experience is the result of poor judgement."

View waho6o9's profile

waho6o9

7176 posts in 2042 days


#14 posted 04-07-2016 03:43 PM

A great pictorial on making a fine saw great work Norm, thanks for sharing.

View AgentTwitch's profile

AgentTwitch

528 posts in 2962 days


#15 posted 04-07-2016 05:39 PM

Thanks, everyone. It means a lot to have so many talented craftsmen commenting.

-- Regards, Norm

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