Lee Valley Tools Woodworking Newsletter
Vol. 1, Issue 5
July 2007
Custom-Made Saw Handles

Marking the centerline.
Shimming up the blade to cut the blade kerf.

If the handle is for a backsaw, now's the time to chisel out the mortise for the back. Then check the fit of the blade in the kerf and whether the back edge of the blade is lining up with your previously marked line (this is important if you're trying to line up with existing bolt holes). Once you're happy that you have the bolt locations marked correctly, bore them on the drill press. Don't forget a counterbore if required. Refit the blade and try fitting the bolts. If they're slightly off, don't panic—use a scribe or tip of a needle file to scratch the hole location. Remove the blade and use a round needle file to enlarge the hole in the required direction. If need be, a cobalt drill bit will make quick work of drilling another hole in the blade. Don't worry—many old saws have more holes in the blade than a chunk of Swiss cheese and they still work fine.

Bolt holes
The counterbored bolt holes.



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