Sawdust Maker

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Project by ErikF posted 11-18-2013 12:14 AM 1767 views 2 times favorited 11 comments Add to Favorites Watch

Here is a saw I made. It has a cocobolo handle, slotted copper back, .032” 1095 steel blade, and split nut screws. The saw took a lot of trial and error to get it cutting smooth. I first toothed it at 9 TPI but ran into issues right away. The teeth bit way too hard in anything besides doug fir to be practical, I tried filing the teeth with a bit less rake to them but it is a heavy saw with wide teeth, it wasn’t going to work. I refiled it to 11 TPI with a mild rake angle and it ended up being the right combination for cut speed and smoothness. It still has a bit of grab when starting the cut but it goes smoothly after that.

I’ve got a blog going on how I build these and will be adding more of the steps I take to make the saws. Quick note on the copper spine: it is must slower to mill when compared to brass.

13 3/4” Blade Length
4 5/8” Cut Depth
19” Overall Length
Back 1/4” x 1”

-- Power to the people.

11 comments so far

View Dusty56's profile


11777 posts in 2731 days

#1 posted 11-18-2013 12:45 AM

The handle is gorgeous and the overall tool is a thing of beauty : )

-- I'm absolutely positive that I couldn't be more uncertain!

View waho6o9's profile


6314 posts in 1620 days

#2 posted 11-18-2013 12:58 AM

Outstanding work!

View DocSavage45's profile


6607 posts in 1885 days

#3 posted 11-18-2013 01:09 AM

my fist thought was”nice work.”

-- Cau Haus Designs, Thomas J. Tieffenbacher

View CL810's profile


2977 posts in 2031 days

#4 posted 11-18-2013 01:52 AM

Great saw.

-- "The only limits to our realization of tomorrow will be our doubts of today." - FDR

View JeremyPringle's profile


317 posts in 1517 days

#5 posted 11-18-2013 02:39 AM

This is pretty awesome. I dream about making my own saws. I just finished making my first re-handle for an old disston.

View ErikF's profile


449 posts in 1287 days

#6 posted 11-18-2013 03:17 AM

Thanks, Gents. The need for a new saw handle is what got me started. It is pretty fun once you get the filing figured out,you can try different toothing patterns and tooth geometry.

-- Power to the people.

View Jim Jakosh's profile

Jim Jakosh

14018 posts in 2148 days

#7 posted 11-18-2013 03:25 AM

Beautiful saw, That must have taken a lot of time to file and then re file all those teeth! Glad you have a combination that works now!................Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View bobasaurus's profile


1940 posts in 2227 days

#8 posted 11-18-2013 05:42 AM

I love custom-made tools, and this looks fantastic. The copper and cocobolo look great together. Most dovetail saws have finer teeth, as you’ve found… maybe try 14 ppi or higher on the next one. I think mine is 18 ppi.

-- Allen, Colorado

View ErikF's profile


449 posts in 1287 days

#9 posted 11-18-2013 11:42 AM

You are right about the higher tooth count for the more dedicated dovetail saws. I recently did an 18TPI and it cuts dovetails nicely but struggles with tenons because the shallow gullets fill up quickly.

-- Power to the people.

View Fishinbo's profile


11362 posts in 1218 days

#10 posted 11-21-2013 05:42 PM

That’s one cool and tough saw. Like the gorgeous handle and awesome blade. Great job!

View Schwieb's profile


1692 posts in 2504 days

#11 posted 11-27-2013 01:01 AM

beautiful saw. fine work

-- Dr. Ken, Florida - Durch harte arbeit werden Träume wahr.

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