Full Chisel Blog

February 12, 2009

Tenon Saw – Compleat

Well, bowing to pressure I finished the Tenon Saw with the exception of the finish.  I used a regular twist auger for the knob hole but used a larger center bit to drill the two holes for the handle, almost a perfect match for the shape of the ends of the handle.

Tenon Saw holes

I put it all together and it worked great.  After the photo shoot, I glued the knob and handle into the body of the saw.  The blade fits tightly into the kerf and I will use very small wooden wedges to keep it in position.  However the blade is quite tight in the kerf, so slipping may not be a problem.

Tenon Saw Compleat

Now all I need to do is put a coat of linseed oil on everything.



  1. Very, very cool, Stephen. Sorry if you already covered this, but did you say where you got the blade for your saw?

    Comment by the Village Carpenter — February 12, 2009 @ 5:08 pm

  2. VC,

    I am sorry, I did not mention the blades origin. It is/was on old Disston, but not that old, it had/has a carved wheat beech handle, with several fractures and brass saw bolts. The blade was marked X under the handle but it wasn’t taper ground. It had been sharpened a number of times, had seen much wear and had a kink with a fracture, so I sacrificed the saw.

    I cut it with some tin snips, did a bit of grinding and will get around to sharpening it, although it seems to work fine now. I also have the remaining saw which I will fashion into another saw. I also have a large piece of saw steel to cut up into card scrapers. After scraping the handle of this saw, I need a narrower card scraper to get into the tight inside curves.


    Comment by Stephen Shepherd — February 12, 2009 @ 6:15 pm

  3. It look realy cool, I like it abbility to cut angled tenon. Verry good work.

    Comment by David Gendron — February 12, 2009 @ 7:07 pm

  4. The saw is looking good. Why not some slot the blade as in a stair saw so you will have built in depth adjustment?
    Thanks for making this and showing us. Very cool.

    Comment by Roger Nixon — February 13, 2009 @ 12:11 pm

  5. David,

    The ability to cut angled tenons was what spurred me on to make this tool.


    I actually thought about using my stair saw (which I made years ago and have never used) as it could be used on its side. After using the new saw a little, I have decided that the adjustment is probably not necessary. I left the blade sticking out of the body more than I intended (cutting that long slot was interesting) and more than it is shown in the illustrations.

    I still need to make the bilboquet to do the layout, although it is not necessary, all that is required is to mark the layout lines on the end of the tenon and position it properly in the clamp. (The bilboquet is that set up tool and can be adjusted to mark out the tenons).


    Comment by Stephen Shepherd — February 16, 2009 @ 7:06 am

  6. […] We all had a good time, spent some quality time at Woody’s and they invited me back, might be doing the tenon saw/clamp. […]

    Pingback by Tool Making Workshop « Full Chisel Blog — March 13, 2011 @ 7:29 pm

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