Making my own dovetail saw - Woodworking Talk - Woodworkers Forum
 
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post #1 of 20 Old 05-06-2013, 11:26 PM Thread Starter
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Making my own dovetail saw

I've been kicking around the idea of building my own dovetail saw. I wanted to use readily available supplies that I can get locally. I've already started, but want to get ideas from all of you. What would you use? Any good resources? Experiences?
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post #2 of 20 Old 05-07-2013, 02:03 AM
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Spring steel shim stock and brass flat bar.


What are you working with?
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post #3 of 20 Old 05-07-2013, 09:46 AM Thread Starter
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Gonna try copper instead of brass. I can forge a spine from copper pipe. I have a donor backsaw that was $5 new. I will cut it down to size. Handle is gonna be mesquite because I have a bunch to work with.
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post #4 of 20 Old 05-07-2013, 10:15 AM
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If the donor saw has impulse hardened teeth steer clear. The rest of the saw plate will not be tempered well for a saw.
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post #5 of 20 Old 05-08-2013, 08:25 PM Thread Starter
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Here is the handle. I got the template from TGIAG site.

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Making my own dovetail saw-image-3701648354.jpg

I used a rasp for the shaping then sanded it to 320. I like Danish oil so it will get a few applications.
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post #6 of 20 Old 05-08-2013, 09:55 PM
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Nice job! What are your plans for hardware?
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post #7 of 20 Old 05-08-2013, 11:45 PM Thread Starter
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I have some saw nuts from a basket case handsaw. They are brass, but should work. Here's the blade with the folded copper back.

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I cut a 14" Great Neck saw down to 10". The teeth are the same color as the rest of the plate, so I assume the are not hardened.
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post #8 of 20 Old 05-09-2013, 12:07 AM
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Man, that's really looking great! How did you fold the copper? A brake or a jig, or...?
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post #9 of 20 Old 05-09-2013, 12:19 AM Thread Starter
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I did it the hard way wit a ball peen hammer and s a steel ate. A press ang a sheet metal break would have been game changers. Got it flat, then used a vise to hammer the plat 90•. After that lost of taps to get it as uniform as possible.
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post #10 of 20 Old 05-09-2013, 12:23 AM
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That is some great work!

Are you going to re-tooth the saw or is the tpi suitable for your use?

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post #11 of 20 Old 05-09-2013, 11:51 AM Thread Starter
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The teeth are the right ppi so I will just set and sharpen. Sorry about the grammar in my last
post. I was in a hurry and I have fat thumbs.
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post #12 of 20 Old 05-09-2013, 05:54 PM Thread Starter
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I forgot to say I used a belt sander to clean up the spine. That's why it looks so clean.

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Here is the handle slit and test mounted to the plate.
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post #13 of 20 Old 05-09-2013, 09:28 PM
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Quote:
Originally Posted by EastexToolJunky View Post
I forgot to say I used a belt sander to clean up the spine. That's why it looks so clean.

Here is the handle slit and test mounted to the plate.
Wow! That looks terrific!
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post #14 of 20 Old 05-09-2013, 11:41 PM
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That looks really nice. Copper for a spine looks great, and you nailed that tote.
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post #15 of 20 Old 05-10-2013, 10:33 AM
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By what means do you cut the slit in the new handle? Do you use the saw blade that will finally be inserted? I have a dovetail saw that needs rehandling and have wondered how to do this.
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post #16 of 20 Old 05-10-2013, 02:17 PM
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Here's a good tutorial on making saw handles.

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post #17 of 20 Old 05-10-2013, 02:22 PM
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Very nicely done. The handle looks especially nice. Great job. Ralph
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post #18 of 20 Old 05-10-2013, 08:50 PM Thread Starter
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I used my Veritas gents saw which has a very small kerf. I used my wheel marking gauge to mark the centerline, then just cut to the line. The blade fit was tight, so I ran the saw lightly through the kerf a few times to hog it out a bit. The tough part was chiseling out the slot for the spine. I didn't have a chisel narrow enough. I sharpened a piece of 3/16 drill rod to pare out the back and bottom. I just took my time and kept test fitting.
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post #19 of 20 Old 05-10-2013, 08:58 PM Thread Starter
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I like the like to the saw handle tutorial. I wish I had drilled the holes first, dangit. I'll just have to be careful so all of my shaping wasn't a waste.
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post #20 of 20 Old 05-10-2013, 08:59 PM Thread Starter
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Link not like.
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