A 16″ tenon saw is in the works, and I needed to gather all the components together before I started the job. In this post I’ll talk about where I got all the pieces – no point in talking about how to make the saw when there are many sites that explain the saw making process much better than I can hope to. The most appropriate walk-through sites I have found include these by the Alaskan Woodworker, Bob Rozaieski, the Literary Workshop, Norse Woodsmith, and Ray Gardiner.
- Firstly (and this was the easy part) I got a 0.025″ thick, 16″ long saw plate from Ron Bontz along with a 3/4″ deep brass spine. Ron cut a tooth pattern in the plate for me. I went with an 11 tip rip.
- Nuts and a medallion are slightly harder to find. eBay has some on offer every now and again, but you must be careful to differentiate between the handsaw and back saw sized-medallions; 1″ and 13/16″ respectively, according to the Disstonian Institute. I guess this might not be critical, though. I received some old nuts and a medallion from ‘Joe’s used tools’ back when that fine website was in operation. I show a quick way to polish the brass hardware in this video.
- The handle is definitely the most daunting part of the task. To start with we need either our own design or to use a pattern. As I wanted my saw to be similar to the Disston D4 handle I have on the carcass saw, I found a D4 pattern on the TGIAG website. Other patterns are available from Mike Wenzloff, Blackburn Tools and on Backsaw.net. I did modify the pattern to incorporate a lamb’s tongue into the design – just because it is a little flourish that looks nice. All that is left is to find a nice hardwood blank about 7/8″ to 1″ thick.
I found my first attempt at making a handle was very crude. I wish I had practiced on some cheap stock rather than the nice walnut I had put aside for it. In the end I made a second and much better looking handle out of mahogany.