Making a dovetail saw from spare parts

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I had intended fixing up an old Disston saw but the plate was damaged beyond repair, the saw nuts were mangled. So, I thought of making a dovetail saw with the parts.

A cheap Buck Bros saw from the BORG was used as the saw plate. It has teeth stamped in at 16ppi, but it would be a good user I think. I cut the donor blade to length and width using a hacksaw.

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I roughed out the shape of a handle in pine and practiced cutting the mortise for the spine and cutting out for the plate.

Test fit with the practice handle, blade, and spine.

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Marking out for the new handle from a block of Brazilian Cherry (Jatoba) that was a left over from a flooring project

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Roughing out with holes cut on the drill press. The wood just laughed at the augur bits.

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After cutting with the bandsaw.

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Chiseling in the mortise for the spine. Followed up with cutting the slot for the blade.

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I found the stock was too wide for the saw-nuts to close. So, I had to scrub plane it down to thickness.

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I cut the spine to length and filed off the rough corners. Here is a test fit before I went too far with the shaping. I cut it so that the logo would be halfway along the visible length.

At this point it is a serviceable tool.

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Rasping, rasping, and more rasping. This took a LOOONNGGG time. This is the point you start to question your sanity.

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After rasping and filing the lump of wood now looks like a handle.

Next test fit with the spine and blade. A bit of water added to see the color of the handle.

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A couple of coats of shellac with sanding between them.

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Test fit of the saw nuts again after polishing them up. I thought they were a bit too fat, or that I had filed the edge back to close.

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So, I filed them down to reduce the diameter. I also drilled out the handle more so they would sit in deeper.

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I then filed the bolt and nut flush with the surface.

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After some final sanding and a wax applied with steel wool it looks the part. Cuts well too after I sharpened some proper teeth into it.

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All in all this exceeded my expectation. I would highly recommend taking a rasp to a piece of wood and seeing what you can make.

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