| Blog series by Ron Aylor | updated 04-15-2018 11:28 PM | 4 parts | 7968 reads | 57 comments total |
Part 1: The Want
The Want - For years I have been resawing stock with a rip cut handsaw … both hardwoods … … and softwoods. Although this has proven successful, I have always wanted to add a frame saw to my arsenal, for this purpose. I have hesitated, up to now, for the sole reason of blade attachment. I have seen many different methods using tubular steel with inset bolts for blade tension, but I do not have the capacity to work with metal. I recently obtained a copy of TOOLS: Working Wood in Eight...
Part 2: Handles
Handles - Having cut out the first handle with a coping saw, I used files and rasps to further define the shape. I then transferred the shape to another cherry board and started all over again. I think these two handles are pretty close … ... especially when viewed at three feet apart … LOL! Overall this saw will be approximately 40” long and 20” wide. Next I need to cut the 3/4” x 1” side rails, and joint them, via through mortise and tenon, to the handles before tac...
Part 3: Cart Before the Horse
Cart Before the Horse – I know I said I was going to attach the side rails next, but as I was ripping these parts … … it dawned on me that I didn’t know how long they needed to be. I wouldn’t know the length until the blade attachment pieces were in place. So, once I laid out their shape on a cherry board, I drilled holes for the blade pins … … cut mortises for the handles to pass through … … making sure everything stayed square … … and tight. ...
Part 4: Side Rails and a Test Drive
Side Rails and a Test Drive – After reorienting the horse and the cart, I used my tenoning clamp & chairmarker's tenon saw ... … to create a tenon at one end of each of the two 3/4” x 1” cherry side rails. I then cut 3/8” x 3/4” x 1-3/8” through mortises in the handles … ... to accept the side rails. After a quick check for squareness … I assembled one end of the saw and attached the blade … … It was then that I was able to determine the len...
