Cocobolo handeled Carcass Saw

[Klaus Kretschmar]

Hi Creekers,

after making saws together with Pedder for about 2 years now, we realized that we´ve made quite a number of customized saws - but not for ourselves. Our own saw tills look poor when looking for a TLT saw http://www.ukworkshop.co.uk/forums/images/smilies/icon_confused.gif So we decided to make some saws for ourseleves in 2011, too.

The first was a 14" Carcass Saw with Cocobolo handle. Pedder shows his one on our blog

I want to show mine here.

It´s Carcass Saw in the sash saw size. Blade length 14"; depth at the heel 3", at the toe 2-3/4"; thickness 0.020" (I like fine bladed saws). It´s toothed cross cut to 11 TPI. The closed handle of mine got a slightly different design compared to Pedders. The top horn is a little thinner, the hook has curved chamfers to make it look some lighter and the dolphin cut is slightly deeper. Some pics:

http://1.bp.blogspot.com/-7k6_HC0q78A/TY2dUoy_G0I/AAAAAAAABKY/C4ACHv8z6lo/s1600/P1020113.JPG

http://4.bp.blogspot.com/-Rj5WzZ8dwR4/TY2b2arH5XI/AAAAAAAABJo/JjTpbiP5tUM/s1600/P1020106.JPG

http://2.bp.blogspot.com/-rvIvKCyWMRw/TY2b2lUsBAI/AAAAAAAABJw/wzssw_WaRkA/s1600/P1020107.JPG

The lambs tongue is relatively deep cut, 2 close-ups to show it:

http://2.bp.blogspot.com/-b9lgegvrDXk/TY2b2ARCBrI/AAAAAAAABJg/QHE72FpipTQ/s1600/P1020097.JPG

http://3.bp.blogspot.com/-VjmK4R0gfq8/TY2b2Ct3wLI/AAAAAAAABJY/d_pigx_lsLA/s1600/P1020098.JPG

The saw cuts quick and true but ... it´s a bear to start http://www.ukworkshop.co.uk/forums/images/smilies/icon_lol.gif It requests a start on the pull stroke, what I´m not a real fan of.

Klaus

[Matthew Dunne]

Beautiful!

[Tony Zaffuto]

One of the nicest saws I've ever seen! Can you explain the details of making the handle? The lamb's tongue looks so crisp and the overall shaping is just perfect! Maybe let us in to secret of what tools you use?

[Jeff Wittrock]

That saw is just beautiful!

[george wilson]

As usual,beautiful and immaculate work!!!!!!

[Jessica Pierce-LaRose]

Wow. Just gorgeous!

[Terry Beadle]

That's not a saw....it's a work of art.

However, USE IT !

What a beauty ! Great job. Some where there's a "You Suck" just waiting to be awarded....and a big drop from the Gloat Bird too.

Thanks for posting such a piece. Man, envy grows too quickly.

[Dave Beauchesne]

Klaus:

That is a truly exquisite piece - well done!

Dave Beauchesne

[Bruce Page]

Extremely well done!

[Klaus Kretschmar]

The lamb's tongue looks so crisp and the overall shaping is just perfect! Maybe let us in to secret of what tools you use?

Hi Tony,

the making of such a deep cut lambs tongue is a little bit time consuming. When sawing out the blank, there�s to consider that you need some space for the chamfers on the Top of the lambs tongue and on the bottom of the cheeks. Here a pic of the handle blank from the above shown saw.

188340

As you can see, there�s a cut between lambs tongue and cheeks. It�s made with a back saw in the needed depth. This cut enables you to work from both sides against it, at first with a (sharp!) chisel, then with a carving knife. The most shaping is done by using the carving knife, I use a some little Two Cherries carving knives. The fine Gramercy saw handle makers rasp is very helpful, too.

188341

For the smoothing of the surfaces between lambs tongue and cheeks I use a Japanese saw file. This hint came from a SMC member, I think it was George but I�m not sure. It works absolutely fine. I use one that is toothed only on one side.

188342

After that is done the areas have to be sanded. I use a thin and flexible nail file which will be wrapped with sanding paper in different grits.

Regards
Klaus

[Klaus Kretschmar]

Many thanks to all posters, your comments make me feel fine!

Klaus

[Jim Koepke]

Very nice work.

Thanks for sharing.

jtk

[gary Zimmel]

Real nice eye candy Klaus.. Thanks for the look see.

[george wilson]

Those Japanese saw files are about the sharpest edged files out there!! I have both double and single side ones also.

[Tony Zaffuto]

Klaus,

Your workmanship gives us all something to aspire to! I've seen a lot of saws posted here and on other forums, but this one tops them all! It hits the perfect balance in all senses!

T.Z.

[Jonathan McCullough]

Ausgezeichnet! Klaus, do you find yourself rounding over the corners of the grip portion with a sharp chisel or an incannel gouge? I find that knocks off a lot of material, and it gets things pretty close before I go on to the rasp.

[Klaus Kretschmar]

Ausgezeichnet! Klaus, do you find yourself rounding over the corners of the grip portion with a sharp chisel or an incannel gouge? I find that knocks off a lot of material, and it gets things pretty close before I go on to the rasp.

Hi Jonathan,

The first shaping on the grip edges I do with a "Iwasaki carving file". It´s sold in North America by LV. That is an astonishing tool that works as fast as a coarse rasp but it leaves a better surface and is better to steer. Here a pic of a Pear handle blank that I took to show the difference between that carving file and a coarse rasp when I did a review of this tool.

188411

As you can see, one edge is done with the carving file, the other one with a coarse rasp. The speed was about the same, the result differs ...
I don't feel the need to prepare the edges with a chisel or a gouge since the work on a edge like in the pic shown is done in less than 2 minutes. The further rounding of the edges will be done by using the Gramercy saw handle makers rasp which is an amazing tool, too.

Klaus

[Pam Niedermayer]

Those Japanese saw files are about the sharpest edged files out there!! I have both double and single side ones also.

They are sharp, just got a load of them from a CA seller who got them NOS in Japan. Amazing. And the tiniest ones, 50mm, are exquisite. Of course, the 75mm and 100mm are easily available, from LV IIRC. Now I need to learn how to sharpen these Japanese saws. :)

Klaus, beautiful saw.

Pam

[Salem Ganzhorn]

Wonderful! Makes me want to make a saw handle. The curves and angles and wood are beautiful!
Thanks for posting!
Salem

[Jonathan McCullough]

I agree--those Japanese file/rasp thingees are really nice, and that sawmaker's rasp from Tools for Working Wood is just excellent. Have you tried the Microplane rasps? They're really quite impressive.

This one (http://us.microplane.com/30001rigidraspfor12hacksawframe.aspx)'s good for rough work. I have an old hacksaw frame this fits in and it works really well for the convex parts of the horns.

This one (http://us.microplane.com/30011roundlargeraspwithhandle.aspx) is good for the same stuff as the Japanese carving file.

[Thomas Kila]

This saw looks "almost" as good as the dovetail saw Klaus and Pedder made for me last year :) That is definitely my favorite DT saw - not only for its aesthetics, but also due Klaus' exquisitely shaped handle. I truly love its feel in my hand. And Klaus, I'm glad you finally made something for yourself! Use it in good health!

[Jim Neeley]

That's the finest looking saw handle I've ever seen... :)

[Klaus Kretschmar]

I agree--those Japanese file/rasp thingees are really nice, and that sawmaker's rasp from Tools for Working Wood is just excellent. Have you tried the Microplane rasps? They're really quite impressive.

This one (http://us.microplane.com/30001rigidraspfor12hacksawframe.aspx)'s good for rough work. I have an old hacksaw frame this fits in and it works really well for the convex parts of the horns.

This one (http://us.microplane.com/30011roundlargeraspwithhandle.aspx) is good for the same stuff as the Japanese carving file.

Thanks for the hint, Jonathan. I hadn´t the possibility to try Microplane rasps yet. But what I've read and heard about it, those must be very good performing tools, too. I'd like to know if somebody did a test of the Microplane rasp and the Iwasaki carving file. Both seem to address the same purposes.

Klaus

[Klaus Kretschmar]

Another time many thanks to all posters for your very appreciated comments!

Klaus

[Paul Erickson]

Hi Jonathan,

The first shaping on the grip edges I do with a "Iwasaki carving file". It´s sold in North America by LV. That is an astonishing tool that works as fast as a coarse rasp but it leaves a better surface and is better to steer. Here a pic of a Pear handle blank that I took to show the difference between that carving file and a coarse rasp when I did a review of this tool.

188411

As you can see, one edge is done with the carving file, the other one with a coarse rasp. The speed was about the same, the result differs ...
I don't feel the need to prepare the edges with a chisel or a gouge since the work on a edge like in the pic shown is done in less than 2 minutes. The further rounding of the edges will be done by using the Gramercy saw handle makers rasp which is an amazing tool, too.

Klaus

Klaus,

Exquisite work. Could you be a bit more specific as to which "Iwasaki carving file" you use? I don't see them at LV, but elsewhere there seem to be three versions of them, course, medium, and fine. I need to make some plane totes, and your methodology seems readily adaptable to that task, but would like to know more details before I lay out the cash for them. Again, wonderful work, and thanks for sharing the methodology with us.

cheers, Paul

[Klaus Kretschmar]

Klaus,

Exquisite work. Could you be a bit more specific as to which "Iwasaki carving file" you use? I don't see them at LV, but elsewhere there seem to be three versions of them, course, medium, and fine. I need to make some plane totes, and your methodology seems readily adaptable to that task, but would like to know more details before I lay out the cash for them. Again, wonderful work, and thanks for sharing the methodology with us.

cheers, Paul

Hi Paul,

thank you. LV sells those files under the item "Japanese Milled-Tooth Files". I use currently the smaller ones but I intend to get the larger ones, too. The longer the stroke, the faster the work.

Klaus

[Paul Erickson]

Hi Klaus,

Thanks very much.

cheers, Paul