Thursday, October 5, 2017

Saw Conversion

I have an inexpensive gents' saw that I'm converting into a pistol-grip dovetail saw. I'll have to remove the saw's handle, cut off the tang and reshape the plate slightly, and then mount it into the new handle I'm in the process of shaping from a piece of 25mm thick oak I had lying around.

The existing saw is OK, though not great. The steel is decent and it cuts well, but its back-spline is a little light. Ideally I'd like to change that for a good stiff, heavy brass one, but I'm not sure that I'm capable. For the moment it can stay with the existing spline; I can always swap it out at a later date with only minor surgery to the new handle.

This is more or less how it will look when it's assembled. Of course, the grip will be shaped so that it's a lot more comfortable to hold.

One thing that's troubling me is the pair of nuts and bolts that should hold the plate to the handle. Traditionally they should be brass split-nuts, in which the bolt (or rather, machine screw) part of the pair screws into a threaded, capped tube. This gives the assembly a very neat look, but as far as I can find they're just not available anywhere in New Zealand except by cannibalizing some from an old saw. I can get some from overseas, but they're quite expensive in themselves, and the postage being demanded by the vendors is eye-watering — one mob in the UK wants £45 in addition to the cost of the fixings themselves!

Well, they're not essential; I want to use them mostly for aesthetic reasons. It would be nice to have some though, not least because I have some missing from some of my other saws that I'd like to replace.


I finished the shaping of the handle, and gave it a single coat of oil just to seal it.

I drilled a couple of small guide holes where the screws will eventually go; there's no point in going any further with them until I know exactly what hardware I've got for them.