Paul Saffold
05-24-2011, 6:44 PM
A while back I picked up a backsaw at a yard sale for $1 that I thought would be a good one to modify.
195666
My original intent was to cut off the plastic handle, make a new one and sharpen it for a tendon saw.
I've only sharpened a few saws, but this one seemed really soft compared to the Disstons that I'd worked on.
So I bought some 1095 spring steel,0.02, from Enco. $26 for 2 pieces 6" X 24". More than enough for someone who doesn't know what he's doing to play around with. So I cut it with a Dremel cutoff blade with the 1095 clamped between 2 pieces of cold rolled from the borg. That helped me cut a straight line and was a good heat sink. Using a Jackson handle that's comfortable for a pattern, I have the blank cut from beech 'cuz that's what I have. It was cheep and there is a good (darn good as it turns out) chance I might flub my first attempt.
195665
The slot and mortice for the back are done. The holes are drilled for the saw nuts.
Chicago bolts from Lee Valley.
195668
I marked the hole locations on the blade and with a little butane torch, annealed the 2 spots.
Now I want to make sure I get the holes in the saw blade exactly where they need to be so I put the blade into the handle and drill the first one. To keep anything from going out of alignment, I put in the first saw nut, then drill the second hole in the blade.
195675
I imagine most or all of you know what went wrong. The handle would not come off. Oh yea, I took the saw nuts out first, but it ain't budging one iota. Then a little light went off in my noggin. I cut the handle off and this is what I have.
195676
Those little "burrs" stick out just over 1/8". Remember I said I had already drilled the holes in the blank for the saw nuts. So the steel I was drilling was not supported directly under the bit.
Lesson learned. I'm glad I cut 2 blanks from the birch when I started. I have some curly cherry to use when I get to where I think I know what I'm doing.
As always, comments and your valuable suggestions appreciated.
To be continued.
195666
My original intent was to cut off the plastic handle, make a new one and sharpen it for a tendon saw.
I've only sharpened a few saws, but this one seemed really soft compared to the Disstons that I'd worked on.
So I bought some 1095 spring steel,0.02, from Enco. $26 for 2 pieces 6" X 24". More than enough for someone who doesn't know what he's doing to play around with. So I cut it with a Dremel cutoff blade with the 1095 clamped between 2 pieces of cold rolled from the borg. That helped me cut a straight line and was a good heat sink. Using a Jackson handle that's comfortable for a pattern, I have the blank cut from beech 'cuz that's what I have. It was cheep and there is a good (darn good as it turns out) chance I might flub my first attempt.
195665
The slot and mortice for the back are done. The holes are drilled for the saw nuts.
Chicago bolts from Lee Valley.
195668
I marked the hole locations on the blade and with a little butane torch, annealed the 2 spots.
Now I want to make sure I get the holes in the saw blade exactly where they need to be so I put the blade into the handle and drill the first one. To keep anything from going out of alignment, I put in the first saw nut, then drill the second hole in the blade.
195675
I imagine most or all of you know what went wrong. The handle would not come off. Oh yea, I took the saw nuts out first, but it ain't budging one iota. Then a little light went off in my noggin. I cut the handle off and this is what I have.
195676
Those little "burrs" stick out just over 1/8". Remember I said I had already drilled the holes in the blank for the saw nuts. So the steel I was drilling was not supported directly under the bit.
Lesson learned. I'm glad I cut 2 blanks from the birch when I started. I have some curly cherry to use when I get to where I think I know what I'm doing.
As always, comments and your valuable suggestions appreciated.
To be continued.