YOUR ATTENTION PLEASE, your attention.

[Simplicity]

Doug,
Now the big question because it is obvious you are developing a fondness for this particular piece of timber.

Now a saw handle,when is the tricky saw slot going in.
The pressure is now on especially since your now emotionally involved.


Cheers Matt,

[doug3030]

... when is the tricky saw slot going in.
The pressure is now on especially since your now emotionally involved.

So far, Matt, all I have done is cut out the shape and sand the saw-marks off.

With that profile defined, I think it best to cut the kerf for the saw-plate and drill the holes for the sawnuts while the handle still has flat sides.

I believe it would be more difficult to do those tasks if the handle shaping took place first.

It is also probably a good idea to cut the kerf as early in the piece as possible as it is the step with the greatest risk of disaster.

I haven't decided what to use for cutting the kerf yet - I need to measure the sawplate and find something with a similar kerf.

[Simplicity]

So far, Matt, all I have done is cut out the shape and sand the saw-marks off.

With that profile defined, I think it best to cut the kerf for the saw-plate and drill the holes for the sawnuts while the handle still has flat sides.

I believe it would be more difficult to do those tasks if the handle shaping took place first.

It is also probably a good idea to cut the kerf as early in the piece as possible as it is the step with the greatest risk of disaster.

I haven't decided what to use for cutting the kerf yet - I need to measure the sawplate and find something with a similar kerf.

Doug Doug,
My whole point your just at the hot lust stage of the dating thing.
I would do the saw slot if it was me right about Now.
If it all goes pear shape you haven’t wasted a lot time on the saw handle.
You still get to shed a tear, but you ain’t in the divorce court screaming your lungs out about all the effort you put into the love affair.

I’ve used a hacksaw blade in the past to start a slim saw slot.
That then can be opened up using the same saw plate you intend to use on the saw.(But with no set)

Cheers Matt.

[doug3030]

My whole point your just at the hot lust stage of the dating thing.
I would do the saw slot if it was me right about Now.

If its all the same to you I will eat my dinner first, before it goes cold

That then can be opened up using the same saw plate you intend to use on the saw.(But with no set)

This is a rehandle job - saw is already set

[Chris Parks]

Mat, I am out for this unfortunately, I really wanted to come down and say hello to everyone but it is not to be.

[Bushmiller]

If its all the same to you I will eat my dinner first, before it goes cold

Ha, Ha. Sounds like a man going in to battle. Remember to have a squat first too!

Rob Streeper identified a good method to me of cutting the saw slot.

1. Mark your kerf with either fine pencil or better still use a marking gauge.
2. With a fine tooth saw without set, saw along the line only to the depth of the teeth. In practice this is probably no more than 2mm.
3. With a similar saw, but with the teeth set, deepen to, say 10mm.
4. Now you can use another saw to open up the kerf to suit the thickness of the plate and cut to the required depth.

The principle is that once you have a shallow kerf all around the slotted part of the handle it is much easier to avoid drifting off.

Since using Rob's method I have not had a failure as far as the saw slot goes (plenty of other disasters). The only drawback with this method is having a number of suitable saws. I have a couple of el cheapo gentlemen's saws I use for the first two steps above. A hacksaw blade as Matt has suggested might also work for opening up the kerf in step 2, but I am not sure how well it would track for the step 1 as it relies on a "wave" rather than "set."

Regards
Paul

[doug3030]

Mat, I am out for this unfortunately, I really wanted to come down and say hello to everyone but it is not to be.

Pity you can't come and join the party Chris.

Rob Streeper identified a good method to me of cutting the saw slot.

...

The principle is that once you have a shallow kerf all around the slotted part of the handle it is much easier to avoid drifting off.

The sawplate is 1.1mm thick.

The blade on my 14 inch bandsaw cuts a kerf 1.1mm thick. I might try an experiment on a piece of the scrap I cut off the sawhandle. I will cut the kerf first with a japanese saw and see if the bandsaw will follow it nicely, against a high fence. The bandsaw is well tuned and can cut thin veneers accurately so I think it might be worth a go.

[Simplicity]

Mat, I am out for this unfortunately, I really wanted to come down and say hello to everyone but it is not to be.

Chris,
Thanks for letting us know, it’s a shame you can’t make it.
But we understand, it’s quite a drive for a one day event.

Cheers Matt,

[doug3030]

In preparation for Matt's weekend, I had a workshop visit today from Benny

Benny came over for a bit of a hand with getting a handle blank started and to make some sawnuts on my metal lathe.

We discussed a few aspects of timber selection for saw handles and used one of the templates from Blackburn tools' website to mark out a handle from some Banksia Benny brought with him.

We had time to talk our way through the lathe work for one saw-nut, with a bit of finishing work to still be done, hopefully next week.

It was a pleasure to have Benny in the shed for the day. He is a young man who is keen to learn, respectful of the equipment and a pleasure to teach. I really enjoyed the day.

Here are some pictures of the day in progress. Benny is the personification of concentration.

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[Simplicity]

Doug/Benn


That looks like a great day of activity.
Well done to you both .
I must apologise for my lack of attention here lately, just a bit going on in my world away from the forum.

But I am very much looking forward to the day which is just around the corner now.

Cheers Matt.

[doug3030]

Doug/Benn


That looks like a great day of activity.
Well done to you both .

It was an absolute pleasure helping Benny spread his woodworking wings a bit wider.

I was hoping he would post a photo or two of his saw handle in progress. It really is well done.

Benny, have you worked out yet when you are coming back to finish the preparations for Matt's day?

[Benny_]

It was an absolute pleasure helping Benny spread his woodworking wings a bit wider.

I was hoping he would post a photo or two of his saw handle in progress. It really is well done.

Benny, have you worked out yet when you are coming back to finish the preparations for Matt's day?

Thanks a lot, I had a lot of fun as well.

I have been pretty busy recently so forgot to post photos. Went straight out of my head after Thursday! Here are the photos of the saw handle, + my first item of metal turning (saw nut). The wood is banksia serrata.

I think Thursday this week at the same time would work fine.

[Bushmiller]

Benny

My conscience says I should warn you of the slippery road to hand saw addiction.

But I'm not going to.

Nice saw handle and timber.

Regards
Paul

[doug3030]

Benny

My conscience says I should warn you of the slippery road to hand saw addiction.

But I'm not going to.

Too late Paul, the bug has bitten him. His eyes glaze over and he hyperventilates when he sees all of my "works in progress". I have to keep them out of sight when he is in the shed.

But hey that is a good thing.

[doug3030]

Nine days out from Matts GTG and Benny is back in my shed honing his skills.

After a quick refresher on how to make sawnuts on the lathe, I left him to it and sat at my bench and worked on some of my own projects.

While Benny was making sawnuts with very little input from me, I was working on my solar power system ready for Easter camping.

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Once the lathe work was done I showed him a jig I made for squaring up the shank on the milling machine. Real easy to use.

20190328_131244.jpg

Benny got the slot cut in his handle for the sawplate using one of my Japanese saws and managed it very well.

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And after I had finished my solar power work I cut the sawplate slot in the thumbhole rip saw handle

20190328_164115.jpg

A great day and lots of learning and skill building took place for both of us.

Looking forward to the GTG