Tenon Saw Detour

The next step on my saw chest it to make the lid.  To do that I need a tenon saw, a mortise gauge and a mortise chisel.  Whoops.

The mortise gauge is on order.  I am getting the 1/4″ mortise blade for my Glen-Drake Tite-Mark.  I love my Tite-Mark, but I wish it had a wider base, round bases are needlessly wobbly.

For the mortise chisel I’m re-working an old English mortise chisel.  It measured .290 wide, and was rusty, so I’m grinding it to .250″ and will do a general tune up on it.  I’ve just rough ground it here, and will be hand sanding it (on a surface plate) to get all of the sides clean and true.  Then I’ll sharpen it, and hopefully not poke any more holes in my hands.

Finally, I need a tenon saw.  I have a Bad Axe Beastmaster that I found on eBay, but it is WAAAY too big to cut a dinky tenon on 3/4″ pine.  I have another Bad Axe tenon saw on order, but I don’t expect to see it anytime soon (14 to 16 week wait list!).  So I picked up this beauty on eBay for cheap.  It has a chip out of the horn and a chunk out of the front of the handle.  It’s pretty rusty, but doesn’t appear to be pitted.

The chip should be pretty straightforward to repair.

The chunk I’m a little concerned about repairing.  I’ll need to cut out enough that I have a straight, flat area to glue in a new piece.  And it needs to be fairly horizontal so I’m not gluing end grain (and to help hide the splice).  It will probably go through the screw hole.  and it’s right on the groove for the blade and back.

First order of business, take it apart.  I scrubbed the handle with a scotchbrite pad in acetone and got all of the old finish and dirt off.  I cleaned the saw nuts in acetone too, I’ll polish them before I put it back together.  The saw plate I treated with Navel Jelly rust remover, two applications.  Then I dried it and soaked it with WD-40 to keep it from rusting inside the back.  I don’t want to take the back off if I don’t need to.

Fixing up the plate is going to be simple, just some detailing and then re-sharpen it.  The handle will take a little more effort, so I’d better get to it.


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2 thoughts on “Tenon Saw Detour

  1. I’m thinking of taking a class on saw making. Sir Matt Cianci lives in the same town I do and he teaches saw sharpening and making. Maybe after a class I could tackle a project like this.

    • Wow, I’d love to take a saw making class with Matt. I saw some pictures recently of saws made in one of his recent classes, amazing stuff.

      Like this one, with a Holly handle.
      from thesawblog.com

      But you could totally do a saw restoration right now. If I can do it…

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