| Project by DHS | posted 204 days ago | 1861 views | 19 times favorited | 18 comments | ![]() |
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I had been searching for a vintage tenon saw for months but could not find one I liked. So, I decided to just build one. After all, how hard could it be? It turned out to be both easier and more difficult than I imagined. The spring steel saw plate was a piece of cake. I ordered one from Wenzloff and Sons (http://www.wenzloffandsons.com). It was relatively inexpensive and they even cut the teeth for me (11 ppi). The handle was trickier but I took my time and after one false start I managed to fashion one out of some figured cherry from the cut-off bin. I copied a handle from an old Disston back saw, but gave it a slightly more aggressive hang. I cut the handle to shape using a bandsaw, scroll saw, and drill press. I carefully shaped it using rasps, files, chisels, and lots of sanding. Cutting the slot for the blade was probably the most challenging part. I used a thin-bladed carcass saw that cut a kerf the same width as the tenon-saw blade.
By far, the most difficult operation was folding the brass spine. It was much harder than I had expected. I went through a few pieces of brass before I got it right. In the end, I used 2” wide 0.093” thick formable brass (Alloy 260, McMaster-Carr). I visited a friend of mine in his machine shop to bend it (see collage of photos). I made the initial fold using a sheet metal bending brake. I carefully squashed the spine some more using an arbor press. I then hammered it like crazy against an anvil to flatten it. It took a lot of sanding to remove the mallet marks. And it took a lot of bending and tweaking to get it straight. I tapped it onto the back of the saw plate with a mallet.
After setting and sharpening the teeth, I’ve got one serious tenon saw. If you are interested in making a saw like this, there are a few web resources that I found quite useful.
http://norsewoodsmith.com/content/backsaw-project
http://www.backsaw.net/SawHandles101.pdf
http://www.wenzloffandsons.com/pdf_docs/kit_instructions-back-saw-Full_Kit2.pdf
-- Dave S., Bellingham, WA
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18 comments so far
HillbillyShooter
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1433 posts in 489 days
#1 posted 204 days ago
That is just too cool! Looks like you did a great job. Thanks for sharing.
-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington
shampeon
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570 posts in 381 days
#2 posted 204 days ago
Wow, looks great!
What did you use for the saw nuts? Also from Wenzloff?
-- ian | "You can't stop what's coming. It ain't all waiting on you. That's vanity."
jap
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1073 posts in 251 days
#3 posted 204 days ago
nice, i never knew you could buy just blades
-- Joel -- http://diversitywoodworks.wordpress.com
DHS
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93 posts in 1421 days
#4 posted 204 days ago
Yes. You can just buy blades. In fact, that inspired me to make this saw. I spotted a restored “vintage” backsaw on ebay with a new blade. The seller stated that the blade came from Wenzloff and Sons. That saw sold for two hundred bucks! I checked the Wenzloff and Son’s web page and discovered you can purchase a blade for around $16.00. I immedately ordered a blade and then had to figure out how to make the rest of the saw.
-- Dave S., Bellingham, WA
waho6o9
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3066 posts in 774 days
#5 posted 204 days ago
That’s a great saw Dave, good job.
Thanks for posting all the details as well.
CodyM
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46 posts in 1017 days
#6 posted 204 days ago
Wow, that is one nice saw! Great job! What is the depth of that thing under the back? Also was there a long wait for the saw plate?
-- Cody - Salt Lake City, UT
DHS
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93 posts in 1421 days
#7 posted 204 days ago
cody – The saw is 16 inches long and has 5-inch depth of cut. I think it took around two weeks for the blade to arrive.
-- Dave S., Bellingham, WA
Dennisgrosen
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10851 posts in 1312 days
#8 posted 204 days ago
congrat´s with a well done job
may it serve you well :-)
Dennis
walden
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65 posts in 219 days
#9 posted 204 days ago
It looks amazing! Well done. I have been thinking of making myself a set of hollows and rounds for moulding applications, but haven’t gotten up the nerve just yet.
chrisstef
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5577 posts in 1203 days
#10 posted 204 days ago
I love this …. for $16 you get the plate, make a handle (free), and squish the brass spline on. A top notch tenon saw.
-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty
WoodworkGuy
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58 posts in 991 days
#11 posted 204 days ago
Outstanding job on a wanted/needed tool that will serve you and your descendants well for years to come.
-- Making sawdust and memories through woodworking. http://woodworkguy.blogspot.com/
bko
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103 posts in 1214 days
#12 posted 204 days ago
That is very nice! Great work—keep going!
Grumpymike
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660 posts in 512 days
#13 posted 204 days ago
Many of us make projects in our shops, but very few of us make the tools to make our projects.
You stand in a very small group with a very large group of admirers.
Great job on that tenon saw. I envy your pride.
-- Grumpy old guy, and lookin' good Doin' it.
bfergie
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67 posts in 513 days
#14 posted 204 days ago
I’ve been looking at those saws on E-Bay as well. How cool to have such an outstanding one that you made yourself!
-- Fergie in CO
Ben
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273 posts in 1911 days
#15 posted 204 days ago
Nice saw. I recently made a dovetail saw in much the same fashion. It ends up being much cheaper money wise and you get to say you made it.
-- Do something nice for somebody
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