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Black grain-filled ash coping saw

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Project by Dave Polaschek posted 11-23-2021 01:57 AM 849 views 0 times favorited 54 comments Add to Favorites Watch

For the 2021 Shop Tool Swap I made a coping saw. It’s made from ash, using the Gramercy Tools Bow Saw pins which are darned handy, and I keep a few sets around at all times.

The saw uses standard 6½ inch coping saw blades, which can be found in any hardware store. But if you like, simply swapping out the cross-bar (and the string) means you can use 12 inch coping saw blades, which are nice in some cases because they cut much faster. I’ve got two saws of each size in my shop, with coarse and fine blades in each length, depending on what I need to do.

After building the saw (picture 5), I wanted to do something to make it special. I’ve grain-filled oak before and thought that might be a nice touch with the ash. I got some black Rockler Wunderfil and diluted it 50-50 with water, then coated the pieces (picture 3), then sanded them back until the only black that was left was in the pores of the wood (picture 4).

After getting the grain filled, I shellacked the pieces. It took about a half-dozen coats to make me happy, and then I used two coats of Behlen Violin Varnish to put a little tougher surface on the tool.

With that done, I tuned the saw. Mostly this involved figuring out the correct tension for it, and I decided that an A440 was in the right ballpark, and took almost exactly 20 turns. I documented this, and other working things that might not be obvious, and included the “instruction sheet” (picture 2) with the saw.

With the saw done, I built a box to hold it which would fit inside a USPS Small Flat Rate Box, then shipped it all off to Eric.

-- Dave - Santa Fe





54 comments so far

View Eric's profile

Eric

2843 posts in 1208 days


#1 posted 11-23-2021 02:18 AM

Great job Dave, and cuts oak like butter.
Thanks again.

-- Eric, building the dream

View pottz's profile

pottz

22315 posts in 2319 days


#2 posted 11-23-2021 02:22 AM

man that is a beautiful saw buddy,im jealous !

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View Dave Polaschek's profile

Dave Polaschek

9330 posts in 1917 days


#3 posted 11-23-2021 02:25 AM

You’re welcome, Eric! Glad you like it!

Well, we tried to talk you into joining, Pottz! Maybe next time!

-- Dave - Santa Fe

View pottz's profile

pottz

22315 posts in 2319 days


#4 posted 11-23-2021 02:31 AM



You’re welcome, Eric! Glad you like it!

Well, we tried to talk you into joining, Pottz! Maybe next time!

- Dave Polaschek


man i wish i could have but i had so much going on,still rapping it up.but hey you see my name on the bowl swap ? bring it on buddy-lol.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View swirt's profile

swirt

7107 posts in 4307 days


#5 posted 11-23-2021 02:33 AM

Nice looking saw with a cool finish.

-- Galootish log blog, http://www.timberframe-tools.com

View Eric's profile

Eric

2843 posts in 1208 days


#6 posted 11-23-2021 02:39 AM

That sounds like a challenge from Pottz there Dave.

Glad to see that he is in on the next one.

-- Eric, building the dream

View Dave Polaschek's profile

Dave Polaschek

9330 posts in 1917 days


#7 posted 11-23-2021 02:45 AM

We’ll see, Pottz. I’ve got a couple ideas…

Thanks, Swirt! I’m pretty pleased with the way it came out, and it sounds like Eric is going to put it to good use.

I figure I’ll come up with something, Eric. And it says it doesn’t have to be a bowl, so…

-- Dave - Santa Fe

View Eric's profile

Eric

2843 posts in 1208 days


#8 posted 11-23-2021 02:50 AM

That is true Dave, who knows what’s going to come out of this one. There is a wide open area there. I think I read in there that it doesn’t even have to made on a lathe.

-- Eric, building the dream

View Oldtool's profile

Oldtool

3403 posts in 3525 days


#9 posted 11-23-2021 02:57 AM

Very nice, makes a great swap.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View Dave Polaschek's profile

Dave Polaschek

9330 posts in 1917 days


#10 posted 11-23-2021 03:04 AM

Yep. I’m trying to think outside the box a bit, Eric.

Thanks, Tom!

-- Dave - Santa Fe

View pottz's profile

pottz

22315 posts in 2319 days


#11 posted 11-23-2021 03:08 AM

lookin forward to this one,sounds like idea’s are flowing.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View therealSteveN's profile

therealSteveN

9387 posts in 1909 days


#12 posted 11-23-2021 08:05 AM

Cool build Dave. The blacked out Ash looks very good, plus a well tuned Bow saw is a thing of beauty anyhow.

-- Think safe, be safe

View Dave Polaschek's profile

Dave Polaschek

9330 posts in 1917 days


#13 posted 11-23-2021 12:05 PM

Yeah, Pottz. We’ll see…

Thanks, SteveN! After using even cheap hardware store blades in a bow saw like this, I wonder that anyone buys the cheap metal coping saws. They’re just so much worse.

-- Dave - Santa Fe

View doubleDD's profile

doubleDD

10918 posts in 3378 days


#14 posted 11-23-2021 12:43 PM

Nice build Dave. I like the darkened grain that gives off the torched effect. I’ll have to look into those bow saw pins too. Great tool to have.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Dave Polaschek's profile

Dave Polaschek

9330 posts in 1917 days


#15 posted 11-23-2021 01:06 PM

Thanks, Dave! I think it came out pretty sharp looking.

I think I’ve bought something like 8 or 9 pairs of those pins so far. I’ve also got some brass stock to make my own if I get super-motivated, but more likely I’ll find other uses for that.

-- Dave - Santa Fe

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