Another saw handle!

[Graywolf]

A few weeks back I had a request to re handle a mitersaw. I though it would be fun to document the process.

I choose a piece of quarter sawn walnut.

I glued on graph of the new handle, and drilled out some of the curved areas.

This gave me the opportunity to use my bowsaw and cut out the shape.

Now it's time smooth out the cuts and check for square.

Next, will be cutting for the blade and back, then the bolt holes. I'll share that a little later.

 

[danmart77]

Is that one of those French hand stitched files I see in the background?

 

[Mike Davis]

Handle looks great!

 

[Graywolf]

Is that one of those French hand stitched files I see in the background?

Yep!:gar-Bi

 

[Graywolf]

I'll finish it up over the next several days. I've been processing a lot of lumber lately and needed a light diversion. This gives me six or seven projects underway.

 

[David Justice]

Cool! Can't wait to see how it turns out.

 

[Jim M.]

Very cool, can't wait to see it finished, Richard

 

[Graywolf]

So before working another project I decided to continue and start moving toward fitting the blade.

Starting by finding and marking the center of the blank, this also where I generally step back and say dear load don't let me screw this up, or words similar to that.

I'm fortunate in that I have several saws that match or come close to the plate thickness. So all I had to do is follow the line.

I highly recommend flipping your blank often to help maintain a straight cut. Take your time and take full strokes. This saw is a beast and is made to eat wood, it's filed crosscut but will rip just as well, just a little slower in pace and in few minutes I'm down to stop line on both sides.

Next I'll set up for the bolt holes and fit the back into the handle. Ounce that is done I'll mount the blade with the bolts and check make sure nothing is binding or causing twist. From there we will shape it up, fit it to a hand and make it purtty.
until then see ya.

 

[Bear Republic]

Great job, Thanks for sharing that, didn't look too intimidating.

 

[sawman101]

You sure make it look easy Richard! Perhaps your mini demos will entice others who haven't tried their hand at traditional woodworking to give it a go. Great job sir!

 

[Graywolf]

So I had some time today to work a the bench and realized I got ahead of myself. Or was it my photographer (me!) had laid down on the job.

This is where I got to when it dawned on me that I'm a slacker. So I'll start back where I should and for part of this I'll use a stand in board.

This being a re-handle I have to line up the holes already in the saw plate. So aligning the saw with back with the handle. Maintaining the hange angle is important here. Once I'm satisfied with what I see, I select a drill bit that is snug fit to the holes in the saw plate to mark the handle blank.

Just a couple twists and it's marked.

This where the stunt blank comes in. I predrill a 3/32" hole at all the bolt locations all the way through the blank maintaining square.

In this demo I'm using 13/16" spade bit to recess for the medallion it is just that size. I generally drill a little deeper than needed and I'll plane the surface a little later.

So for the other side and all the other counter bores a 1/2" forstner bit works well.

Now to widen the through hole in this case about a 1/4"

And this get us back to here. More later

 

[Graywolf]

More from yesterday,

I carefully use a mortise gauge to center up and mark the area for the saw back to nest into. A little color pencil helps visibility.

A dovetail saw is used to define the side walls up to a point.

A chisel takes the rest of the waste out.

And you slowly adjust for fit.

Now we get to make it pretty and comfortable in the hand. I personally think the grain will speak for its self here, and make you want to use the miter box... just saying... that's been my demented experience.

 

[Plunkett]

Very cool and impressive.

 

[Graywolf]

So this is where this thing starts to show some life.

I'm starting to rough out the contours of this handle.one of the primary tools is rasps.

A few areas using a chisel works better

A card scraper makes easy work of this end grain.

It's starting to look like a saw handle you can get your hand on. It feels good to the hand and looks pretty good to. A little more fine tuning and it'll be ready for some finish. More later!

 

[Graywolf]

So, I didn't want to bore everyone with pics of this piece being detailed. Let's just say some scraping and some light sanding was involved.

Soaked in oil for about an hour, it'll need to hang out for a little while

Several more over the course of the week, from there wax and that should be it. I'll post the finished saw. Later

 

[danmart77]

Coming along nicely. I am trying to bring a small dovetail saw back to life. The screws that hold the handle to the saw blade need replacing.

Do you have a supplier for these unique parts?

Thanks
Dan

 

[Graywolf]

If you want something new, www.tgiag.com would be my first choice. They have split nut saw nuts and are well made. If you are looking for some old ones then I have to direct you to eBay. I personally would go with the new ones.

 

[mbromley]

Excellent looking handle and thank you for all the information walking us through the build process! I always enjoy seeing the process just as much as the final product.

 

[Graywolf]

Just when you thought this one had gone away. Two more coats of oil rubbed out over the past week and two coats of wax today. Oh and I polished the brass a little but old soldiers never forget how to polish brass.

So while working on some other projects last week chose to clean and sharpen the blade. I already was sharpening another saw so what the heck.

I sliped it into one of my miter boxes to give it a run. This is a small saw so I had to pad up the base to cut all the way through. However it ran smooth and cut clean.

So Mike if you bring your box to the Stokes Stomp we can marry these two together and tune the box..

So until then that's where it'll hang. :gar-Bi

 

[danmart77]

Richard have you ever separated the blade from the steel backer? I'm thinking I might try and replace the sawblade on my small dovetail saw.

Not sure about major surgery right now. Next step will be getting the teeth re-cut and set and then I will evaluate if blade update is in order.

Looking at the nice brass screws in your saw makes me jealous. Mine were just too bent and distorted from a hack that took it apart earlier in its life. I would like to find some simple brass screws to keep the handle secured.

For a first effort with this saw I'm OK but I think I'll be doing some more on it if the blade shows some potential. Remember.. I cut on the pull for the last 40 years.

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