Finished the handle with two coats of Danish oil and wax and fitted it to the saw. I got the new brass screws from Thomas Flinn I have sharpened the teeth and set the teeth using a punch and small hammer but I think a new saw file would improve the results.
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Thanks for that Mark, not sure how suitable mahogoney is for saw handles? It feels really comfortable I have large hands and I made it to the large template. Because the saw file has lost its sharp edges it produces quite a radius in the root of the teeth. I think a new saw file will enable me to get a more refined tooth shape.
The saw looks fantastic David, hopefully youv created a life long companion tailored to your own hand. Your post is just in time, I have an old Colver bros 14″ tenon that needs its handle replacing before joining my arsenal. Iv been rather apprehensive about giving it a go, my procrastinating keeps letting it fall further down the dreaded ‘to do list’. I know feel far better equipped to give it a go.
As always in this wonderful community that is WWMC many questions have been answered before I had chance to ask them or even consider them myself. Thanks @Serhiy what a great resource. Hopefully I will get chance this weekend to find a handle design I like and make a mock up, maybe one or two different designs, I think that may be the best way to find a handle that ‘Feels’ right in my hand before making the final one, not sure which species of wood i’ll go for, Iv only got oak currently in my hardwood stash that would be the correct dimensions, so i think a little timber shopping may be in order 😉 what a shame 😛
Thanks guys for your kind comments , it was a fun project that I could not have done without the handle templates sticking a full size paper handle template to both sides of my piece of wood certainly simplified the process.
Thomas it was a project that I started and did not finish it till I ran out of other projects
You turned a mediocre saw into something really special. Love the handle pattern and the careful shaping. Great Job!
As far as your rounded gullets, you might try using a smaller file, which would produce a tighter radius (deeper gullet). Many people recommend that the face of your file is 2x the height of the tooth in order to dull the file evenly, but I think it was David Wenzloff that recommends a file just barely larger than your tooth in order to increase gullet size.
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