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Project by ErikF posted 11-18-2013 12:14 AM 1904 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

Dusty56

11806 posts in 3149 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

waho6o9

7172 posts in 2038 days


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

Outstanding work!

View DocSavage45's profile

DocSavage45

7700 posts in 2304 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

CL810

3444 posts in 2450 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

JeremyPringle

321 posts in 1935 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

ErikF

508 posts in 1705 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

17143 posts in 2567 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

bobasaurus

2658 posts in 2646 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

ErikF

508 posts in 1705 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

Fishinbo

11362 posts in 1637 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

Schwieb

1797 posts in 2923 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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