|Project by AgentTwitch||posted 04-07-2016 11:30 AM||1674 views||14 times favorited||26 comments|
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