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Project by ErikF posted 11-18-2013 12:14 AM 1497 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

11659 posts in 2343 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

4925 posts in 1232 days


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

Outstanding work!

View DocSavage45's profile

DocSavage45

5005 posts in 1498 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

2016 posts in 1643 days


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

Great saw.

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

View JeremyPringle's profile

JeremyPringle

281 posts in 1129 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

338 posts in 899 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 (online now)

Jim Jakosh

11473 posts in 1761 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

1259 posts in 1839 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

338 posts in 899 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

11236 posts in 831 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

1521 posts in 2117 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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