I have been longing for a set of tenon saws for a while. Once I moved my saws from my Dutch tool box to a wall rack – there was more room to store them. Just like building highways adds traffic, building hospitals adds patients – increasing tool storage has a way of bringing tools into your life. I used blades, brass and bolts from blackburn tools. The blades come with the teeth punched – but its up to you to stress over which fleam and set you want. The parts for blackburn make for a quick project and leave you with on fleek saws for a fraction of what a new set would cost you. Sharpening crosscuts terrifies me – hopefully these saws perform as smoothly as they feel.
Turns out that sixteen inches is a really long saw. More teeth to file. After years of confusing my rip and crosscut vertias saws – I labelled them with a sharpie. Choosing mesquite and beech accomplishes the same task – with a little more class. PS – If anyone has access to apple wood blanks – I am willing to beg, barter or buy them for my next set of tools. David used antique oil to finish my beech saw – and I used true and tried beeswax on the mesquite.
Blackburn is a great resource on historic handle templates. As long as you can cut to a line and have a handful of forester bits – making a handle isn’t so bad. I actually made a set of templates to sort out whether I wanted the large or extra large pattern. I caught up on my podcasts and rounded everything with rasps.
The challenge is cutting a clean, straight kerf. I got on the right course by screwing a pull saw blade into a jig. I followed up with a rip saw where the set was roughly the same thickness as the new blade. The brass backing fits into a tenon – and than you have to muddle around trying to figure out what hang you want. Photo credits to Rev and her sharp eye.