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Hand Tool Build - Frame Saw

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  • Hand Tool Build - Frame Saw

    I will capturing the progress of my frame saw build for this event. The concept is a simple one; a long blade set within a frame to resaw lumber ... by hand. It's not a new idea but it's something a little off the beaten path. This design is based on improvements of a prototype I made previously that replicates the frame saw style a la Roubo.

    https://en.wikipedia.org/wiki/Andr%C...cage_roubo.jpg

    Obviously most of us aren't cutting lumber from logs like these guys, so the scale of the Roubo design is a little big for what I require. The next iteration is sized appropriately and will have an extended handle to give better balance throughout the cut. Here are some scribblings of my concept and design:

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    I'm using cherry for the build or whatever other scrap I got laying around. I've roughed out the frame and have started the joinery and shaping.
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    Last edited by Allegrus; 08-08-2015, 09:57 PM.
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  • #2

    Re: Hand Tool Build - Frame Saw

    Re: Hand Tool Build - Frame Saw

    This looks amazing! Would you be willing to share your plans when you are finished? - I would love to make one of these. Also, where are you getting the blade?

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    • #3

      Re: Hand Tool Build - Frame Saw

      Re: Hand Tool Build - Frame Saw

      Well, those little scraps of paper you see ... those ARE the plans. I just didn't post all of them. They are to scale so I just place on the wood, trace out the outline and get to work. I will continue to provide the photos of the plans but I doubt I will provide more than this. I could provide specific, critical dimensions after I'm done the build. I will continue to post my hand-drawn designs using old school paper/pencil. Another is ready in fact so when I get home ... I will update.

      The blade is a custom request from Blackburn Tools in the US. The blade dimensions are 3" x 27", 4 1/2 ppi, Premium 1095 spring steel, hardened and tempered to Rc 48-51. Blade is 0.042" thick (not taper ground).

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      • #4

        Re: Hand Tool Build - Frame Saw

        Re: Hand Tool Build - Frame Saw

        Update 2: I cut the M&T joinery for the top brace. Did a dry fit.

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        The dry fit tells me the side arms are 1/2" too long. Actually it was intentional to make the arms longer and see how much to cut off to get the length I was after. Seemed easier than trying to lay it out right the first time. Close up of the stub tenons:

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        Here is the intended design for the top bracket:

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        • #5

          Re: Hand Tool Build - Frame Saw

          Re: Hand Tool Build - Frame Saw

          Better too long than too short
          Looks great
          Jerome
          Canada's South Coast

          Port Colborne On.
          Every loaf of bread is a tragic tale of grains that could've become beer.......but didn't....

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          • #6

            Re: Hand Tool Build - Frame Saw

            Re: Hand Tool Build - Frame Saw

            Fixed my stretchers to the correct length.

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            Made a test cut. Nice and smooth, no deflection.

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            Next step: Figure out some sort of comfortable, removable extended handles

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            • #7

              Re: Hand Tool Build - Frame Saw

              Re: Hand Tool Build - Frame Saw

              I tackled the handle problem. I just turned some spindles and have removable pegs. This is the dry assembly.

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              Here is the arrangement of the drilled holes for the pegs

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              These are the pegs that go in the holes and in their home

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              Also turned some handles. Next I need to figure out the angle to attach them.

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              • #8

                Re: Hand Tool Build - Frame Saw

                Re: Hand Tool Build - Frame Saw

                Quite the saw Mark! Good for you. I'm glad it cut nicely on its first test.
                ______________________________________________
                Rob Brown
                Editor - Canadian Woodworking & Home Improvement

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                • #9

                  Re: Hand Tool Build - Frame Saw

                  Re: Hand Tool Build - Frame Saw

                  Assembled and working ... maybe I will add some embellishment and soften the edges.

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                  • #10

                    Re: Hand Tool Build - Frame Saw

                    Re: Hand Tool Build - Frame Saw

                    Interesting design. Do you find that the extended handle helps c.f. the shorter length you had for the original test cut?
                    Jim

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                    • #11

                      Re: Hand Tool Build - Frame Saw

                      Re: Hand Tool Build - Frame Saw

                      The balance and control is better with the extended handles. My problem with designs I've tried of the traditional design is that they are 'forward-heavy', so the saws are grabby, especially with narrow stock at the beginning of the stroke. Almost had to lift the saw slightly at the beginning while pulling.

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                      • #12

                        Re: Hand Tool Build - Frame Saw

                        Re: Hand Tool Build - Frame Saw

                        You have inspired me! I just bought a blade and hardware for making a frame saw.

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                        • #13

                          Re: Hand Tool Build - Frame Saw

                          Re: Hand Tool Build - Frame Saw

                          Mark, I may have missed it, but wouldn't it have provided better control to keep the two dowels which link the handle to the frame as short as possible? They're quite long to my eye...

                          Great job on the saw!
                          All the best,

                          Marty

                          Secretary of Kingston Wood Artisans Inc. https://kwoodartca.wordpress.com/

                          Master Mistake Fixer (because I've made them all... at least once)

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                          • #14

                            Re: Hand Tool Build - Frame Saw

                            Re: Hand Tool Build - Frame Saw

                            Well, I had a prototype saw that has the shortest possible; none. That saw had no extended handles; I simply pulled it by the mounting frame; just like you see with the Roubo design. The reason for the lengthy handle extension is to move the center of gravity to the front of the blade, ensuring that no matter where the saw is in the cut, the weight of the saw is in the cut, not out in front, bogging the saw down. I suppose I could have corrected with better sawing technique .. but then I wouldn't have a saw to build.

                            The saw is pretty easy to maintain parallel to the cutting plane. I think the extended handle actually helps with that because as the distance from me to the cut increases, I have more ability to correct for angular deviations. Plus, I can sight my saw inline with the bench edge, also parallel to the cutting plane. The main concern is twisting the handles, causing the saw to deflect; addressed almost completely with a kerf.
                            Last edited by Allegrus; 08-29-2015, 07:00 PM.

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