Skip to main content

Making Saw Handles

The saw cannot be classified with any other tool.

Paul N. Hasluck, The Handyman's Book, 1903



I inherited my grandfather's Warranted Superior crosscut panel saw quite some time ago - it is twenty inches long, 10 points per inch, the original handle must have disappeared on some worksite accident in the 1920's (he died in 1952, ten years before I was born). "Pop", my mother and her siblings always referred to him as such, made a replacement handle for it from a piece of oak board. He liked the saw well enough that he used a punch to punch an "R", for Rufus, his first name, into the blade near the handle. Just look it the photo, you will see it. My grandfather, I was told, was an excellent carpenter and when he could afford it he bought the very best tools, or he traded for them. This saw lived in workshop out back of the house when I was young, it was used only to cut down that year's Christmas tree.

A couple of years ago, I removed the original handle with the intent of making a replacement which I never got around to. The dry air of the Colorado Rocky Mountains shrunk the original handle so much it no longer fits the saw.


I do need another panel rip saw, the teeth on my brand new Lie-Nielsen panel rip saw is too aggressive for ripping thin pieces of wood, there was an older Disston "Rancher" crosscut saw left behind by the previous owners of our house. I cut that saw down to match the size and shape of my grandfather's saw.

A friend gave me a short mahogany board which I really had no use for, it was completely flat sawn, but I figured that it would make a good working handle for both saws.


I cut out a piece of that mahogany, thinned it one inch thick, drew the pattern on it and went at it with a brace and bit...



...cut out the handles with a jigsaw..



...then cut the slots with a back saw.



This morning I shaped one handle using files, finished it up with sand paper and applied a coat of Howard's Feed-N-Wax and attached it to the Disston Rancher.



After attaching the handle I discovered I need to teak my design a bit, the lower horn needs a little more depth and sweep and the "finger" that houses the top most nut needs to be a little longer and deeper.

I think I will make those adjustments and make another handle for my grandfather's saw. I would like to find a nice piece of quarter sawn Honduran mahogany to make the handle, I would settle for a pretty piece of alder. I don't plan on using the saw, I do want to build a tool box/chest shrine to house all of my grandfather's tools, to honor him and all those old carpenters I knew when I was a kid.


A nice looking handle! Now, I just need to re-file the teeth on this saw from crosscut to rip.

Now, turn off your computer and go make something!




Comments

Popular posts from this blog

How to Make a Traditional Froe Mallet

What holds the Holy of the Holies, what did Brahma become? Wood. Why will aspen always tremble? For the nails driven into the cross. What makes the color of wood? The soil it tastes. Cradle, fiddle, coffin, bed: wood is a column of earth made ambitious by light, and made of beauty by the rain.

Kim R. Stafford, Having Everything Right, 1986.

Rive, verb, to split
Shake, noun, a split in a piece wood. (Heart shake, ring shake)
Shake, verb, (Middle English), to split.

I know I should have been in the studio working on my back log of guitars, but the day was so nice and warm with a tall blue canopy, I couldn't stay inside. I decided that I needed to make a proper froe mallet. This style of mallet is traditional to northeastern California, primarily Tehama (where I'm from), Butte, Shasta and Plumas counties where making shingles by hand from sugar pines was an industry. I don't know if it was used in any other region along the Pacific Rim, other parts of the United States or even o…

The New Workshop: New Roof, Snow, Rain, Sub-zero Temperatures

A snowflake is one of God's most fragile creations, but look what they can do when they stick together!

Author Unknown


Cold weather and snow delayed me in getting down the corrugate tin roofing on the new workshop. January 3rd proved to be a day of snow flurries and sunshine which at least allowed me to install the roofing. Then it snowed six inches.


The temperature fell to -5 degrees Fahrenheit and it kept snowing...


...until there was 22 inches of snow on the ground. And the temperature fell some more to register -14 degrees Fahrenheit on the thermometer.



Yesterday, the temps warmed up to 36 degrees Fahrenheit with the wind gusting up to 50 mph and we lost power for about two hours.

This morning we woke up to rain and warmer weather. I am very glad that I got the new workshop "dried in" before all this snow fell.



The high reached 40 degrees today with rain and snow flurries, there is a good six inches of slush underneath all the snow. No wind to speak of today, though…

Basic Hand Tool Kit for Making a Classical Guitar, Revised

Ours is really a simple craft.

James Krenov, The Impractical Cabinetmaker, 1979


So, you want to build a guitar.

Since the original post, Basic Hand Tool Kit for Guitar Making, click here to see it, is the most popular post on this blog, I thought I would revisit it and adjust it to what I am using now to make a classical guitar.

The first thing I recommend doing is to buy or borrow copies of the following books:

Guitar Making: Tradition and Technology, by William Cumpiano and Jonathan Natelson
Making Master Guitars, by Roy Courtnall
The Guitar Maker's Workshop, by Rik Middleton

These are required reading before you begin making a guitar.

Also required reading are these books by Roy Underhill:

The Woodwright's Shop
The Woodwright's Companion
The Woodwright's Workbench
The Woodwright's Apprentice


Why these books by Mr. Underhill? You will learn valuable wood working techniques if you make any of his projects. The dovetail joints used to join a drawer together are far mor…