wanted to build a full sized rip and crosscut saws for a
while now. Until recently I didn't have access to large
widths of 0.042" steel. But that changed and I was ready to
Along with that steel I also picked up a
Beverly Slitting Shear. This little gem allows me to cut
spring steel like it was paper. Now that all the pieces were
in place I decided it was time to layout a rip and cross cut
saw prototype. I used AutoCad to design the saw plates to
meet the hang line of a couple of my favorite saw handles -
the Wheeler Madden & Clemson as well as the old Disston D-7.
Once I had these laid out I printed out the plans and went
to town on the saw plates.
Using a trick I picked up from Isaac, I used
blue painters tape to provide a background for my marking
lines. Then it was a simple matter to get the slitting shear
... and start cutting. It went a lot easier
than I would have thought! It was a lot like cutting paper.
It only took me about 10 to 15 minutes
(really took my time here) to cut the saw plates to size.
After that I spent some time smoothing out
the edges and curves with a combination of files and my