Sawdust Maker

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Project by ErikF posted 285 days ago 1480 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


11644 posts in 2322 days

#1 posted 285 days ago

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


4840 posts in 1211 days

#2 posted 285 days ago

Outstanding work!

View DocSavage45's profile


4910 posts in 1476 days

#3 posted 285 days ago

my fist thought was”nice work.”

-- Cau Haus Designs, Thomas J. Tieffenbacher

View CL810's profile


1970 posts in 1622 days

#4 posted 285 days ago

Great saw.

-- "It's amazing how much can go wrong when you think you know what you're doing."

View JeremyPringle's profile


281 posts in 1108 days

#5 posted 285 days ago

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


336 posts in 878 days

#6 posted 285 days ago

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

11329 posts in 1739 days

#7 posted 285 days ago

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


1235 posts in 1818 days

#8 posted 285 days ago

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


336 posts in 878 days

#9 posted 284 days ago

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


11217 posts in 809 days

#10 posted 281 days ago

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

View Schwieb's profile


1499 posts in 2095 days

#11 posted 276 days ago

beautiful saw. fine work

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

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