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By Bluekingfisher
Here is another saw I recently brought back from near death. It is a Disston 6 PPI crosscut saw with a 26" plate. Although in a rough state the plate was good and straight with little pitting. The handle on the other hand had seen some heavy wear. I never really like the " block" shape of the handle so I took the time to reshape it to fit my hand with a little carving for aesthetic.




The first job was to disassemble the saw, a fairly straight forward process.


Getting started in stripping the old finish from the handle, then a little shaping with hand tools to suit my hand.


I cleaned the plate with wet and dry paper then buffed it on a polishing wheel. Once done I set about jointing sharpening and setting the teeth.

I managed to miss a tooth on the first pass, (should have gone to Spec Savers) not to worry, move on.


I use one of these for assisting with the angles invaluable, can't go wrong.


I kept the tooth geometry fairly standard for general cross cutting. A 15 degree rake with 25degrees of fleam.

A little setting and the plate was done.


I applied a couple of coats of stain until I achieved a colour I like then applied several coats of an oil/poly mix. I think about 6 or 7 coats. I let the finish "cook for a couple of days then reassembled the saw.
Last edited by Bluekingfisher on 31 Jan 2018, 19:48, edited 1 time in total.
By Bluekingfisher

The handle looks and feels a lot better, least I think so.




I have completed several more saws, more to come.
By Bluekingfisher
Unless the saw plate is particularly warped, bowed, pitted or the teeth are in a particularly poor state the longest part of the refurb is waiting for the coats of finish to dry on the handles. As a result, I had several saws all in various stages of completion. That way I was assembling one, maybe two saws per day.

Below are some photos, unfortunately I did not take any WIP images of these saws although I can say most were in a similar state to the Disston shown earlier.

Here are the entire batch after completion.


Ranging in tooth pattern from 4 PPI crosscut to 12 PPI rip cut as below.


This one was my grandfathers saw. He died in 1979, it's been hanging on a peg ever since. The teeth were badly shaped so required filing all the way flat to the plate. I kept the original geometry, 6 PPI fil d for cross cut. 15 degree rake with 20 degrees fleam.


The saw below was probably a boot fair purchase some years ago. A non branded saw with three saw nuts. It too was 6 pointer filed for cross cut. I reshape the handle and stained it and polished the saw nuts. When I removed the handle I noticed there were four nut holes drilled so I figured I would add a spare medallion I had. I think it looks better with four, rather than three.




Below is a Spear and Jackson 5ppi rip cut saw. This saw really only required a little cleaning and a touch up of the teeth. The saw below is a small 18" saw with 12 PPI filed for rip cut. On the plate the makers name is "Fitchburg Co, Chicago.


A final one of them all nestling on the saw till a made for them several years ago. At least now they are all ready should I need them and I have just about every conceivable tooth pattern known, with a couple of spares.

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By Brandlin
... when needs must!

Dont worry i DO appreciate quality tools, and would never mistreat anything like your saw collection. It made me jealous to see what you have ...
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By DBT85
Seeing these old saws come back to life gives me hope that I can do the same to the one I got from my recently departed grandfather's garage. All rusted up but with a nice looking handle and a medallion in there. Only 6ppi I think and there might be a slight kink on the blade, but I've not had a real good look at it yet.