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Parts
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This photo shows a walnut handle blank that was cut out with a bandsaw.
The saw nuts are from a trashed Disston rip saw.
The blade is from one of those inexpensive round handled dovetail saws.
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Saw Slot
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This is the roughed out handle after the a cut was made to accept the saw
blade and a channel was cut to accept the brass backing. I used a drill
to hog out most of the waste from the channel and a mortice chisel to clean up the slot.
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Saw Nut Hole Alignment
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I used double-sised tape to hold the saw blade in place while I
marked the location of the saw blade holes with an awl.
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Pilot Holes
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I drilled a pair of 1/16 holes through the handle. This allows me
to drill out the recess on both sides for the saw nut/bolt.
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Recessed Bolt Holes
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This photo shows the recessed saw nut head holes that were drilled
with a fortsner bit. The holes have also been enlarged to accept the saw nut shaft.
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Rounding Over
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The handle was next rounded over with a 1/2 radius bit in a router.
The photo also shows a vertical line that marks the depth of cut for the saw blade slot.
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After Sanding
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After hand sanding.
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After Staining
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I stained with a red mahogany stain. The walnut I used had both
sapwood and heart wood; the stain evened out the color nicely.
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Finished
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After application of 4 coats of garnet shellac and a rubdown with #0000 steel wool.
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More Dovetail and Backsaws
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From top to bottom: A Dission 10" backsaw, Dission 10" backsaw with new handle,
8" dovetail saw with new handle, and a Lie-Neilson 9" dovetail saw.
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