Hand Saw rehabilitation
I have posted pictures of this saw earlier it is the Spears & Jackson Half Rip Saw, with a broken upper horn on the handle. I did not have a large enough piece of beech to do the repair, so I put it off. Well last weekend at the local flea market, I came across this saw, I noticed it had a replacement handle (of beech), so I thought it would be good for doing this repair.

And I thought I could make a new handle for the fine little blade. The blade is old, I don’t know how old, it is 18″ long and is sharpened 16 TPI (PPI) and as a rip saw. The blade has no markings but was re-punched for the new handle.

So, I cut off the horn from the replacement handle and prepared it for gluing. I removed as little of the original as possible to get a flat surface for gluing. I toothed both surfaces and treated them with garlic. I was going to clamp the piece on but ended up just leaving it overnight.
The following day the new horn was ready to shape. I use a #49 & 50 Nicholson rasps to rough shape then went to cabinet files, bastard first then smooth cut. I used a chisel to shape it near the original wood on the top where it curves down then finished with a card scraper. (A bit of hot shellac stick for the fine line on one side that wasn’t quite right).

So with this one complete, I still had that little rip saw to handle up, so I chose cherry to match my other saw handles, and I chose the same pattern for this saw handle.
With a little handling the shine should go away. I matched the color with shellac and burnt umber pigment, it took a couple of thinner applications to get the color without obscuring the grain. Now it is onto the new handle for the little rip saw.
Now I have used these Duck Bill Spoon Bits before but only in pine, so I thought I would put it to the test on some hard cherry, and to my delight the holes were perfect.

Even the exit holes were perfect, sweet bits, I am impressed.
Now yesterday I felt (and actually looked) like that drawing of the Boutique Saw Handle Maker that was on Joel’s Blog. (I should do a vignette). It only took about 10 minutes to cut out the handle and 10 minutes to cut out the hand/grip hole.

The bow saw is a new reproduction made by Clay and is English.
I used the same rasps and files for shaping the handle. I then used a scraper to smooth it out. I cut the slot the the S&J half rip saw (above) as it was the only one I had that was the right thickness for the new blade.

The handle looks big now, some of that is the fact that it is in the ‘white’ and does not have a finish. It will look smaller when it has a finish. I did try out the saw cutting dovetails on some 3/4″ pine and it worked just fine, took a bit longer but produced smooth cuts. I split out the wood to examine the kerf and it was nice and smooth, I can’t wait until I can actually use this fine little saw. Now all that remains until I can really use the saw are a pair of split saw nuts (I think I am on a famous waiting list).
Stephen










































