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Tenon Saw: Thin Plate Stiffened with a Folded Brass Back
A tenon saw is a backsaw: a thin blade with fine teeth, kept straight by a cap of brass or steel folded over its top edge and carried into the handle. It cuts tenons, dovetails and mitres accurately; the back limits how deep it can cut. Make the plate as for the hand saw, file 13 teeth to the inch, fold a brass back onto it, and rivet on a pistol-grip handle.
The picture: two old backsaws with their stiffening backs.
Advanced
Two days
Instructions
1
1
Shear the plate
Shear the plate
Shear a rectangular plate of saw steel about 300 × 90 mm (our size).
Materials for this step:
Saw Plate Steel Sheet1 pieceTools needed:
Plate Shears2
2
Plate, harden and temper
Plate, harden and temper
Harden and temper the plate as in the hand saw blueprint; the teeth are filed afterwards here.
3
3
File the teeth
File the teeth
File teeth at 13 to the inch along one edge, rip- or crosscut-shaped as you need, and give them very little set.
Tools needed:
Bench Vise
Saw File
Saw Set4
4
Fold the back
Fold the back
Fold a brass strip lengthways into a narrow U over a thin bar in the groove of the bottom swage. Slide it onto the top edge of the plate and hammer it closed along its length so it grips tight.
Materials for this step:
Brass Strip1 pieceTools needed:
Bottom Swage
Cross Peen HammerBench Vise5
5
Handle
Handle
Saw and rasp a pistol-grip handle from beech, slot it to take the plate and the end of the back, drill through, and rivet it with countersunk saw rivets.
Materials for this step:
Beech Lumber1 piece
Saw Handle Rivets3 piecesTools needed:
Coping Saw
Wood Rasp
Hand DrillCross Peen Hammer
Metal File6
6
Teeth on the blade
Teeth on the blade
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Materials
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Tools Required
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