I’m proud of two big things on this project;
One being design and execution. The basic mechanics of the saws are really, well, basic. Two uprights, a center cross bar, blade at the bottom, and a Spanish windlass at the top.
And the cross bar being mortise and tenon jointed to the uprights, to provide up/down pivot so that the windlass can tension the blade, but have no twist of pivot in any other plane or axis.
I looked around the Web for ideas, since there are a LOT of these out there, for sale, and home built designs.
But I basically still had to design, engineer and build it from scratch.
Lots of time with measuring, squaring, offseting, re-squaring, and making sure both ends matched.. Etc.
The other thing I’m really proud of, is the fact that I’d Never, Ever cut a mortise and tenon joint before. I did one test mortise on scrap(which sucked!) before I cut on the first saw bar I’d just spent 3 hours making. Yeah, fun. 😉
Cut by hand, chisel and saw. Turned out exceptionally well, if I do say so myself!
The second one even press fit at first cuttings, no trimming needed!! (The first one took 10 minutes of fit/test/shave/test/carve/test/whittle, to get to work, then it was a touch loose…)
Now I know why my Dad hated doing them, and always wanted a power tool for it! I was never taught to cut these, not that I remember. He never got the tool till late in life– he just avoided the joint style.
I actually got him one that attaches to a drill press a couple years before he passed away. It didn’t exactly fit his drill, and he never got to use it before he went. I have them both here, but ironically, I preferred to learn to hand cut them. I’ll get the tool setup at some point soon, but so far, I like doing them by hand!
I Was a bit ambitious in part of my joint design; I copied ones I saw a guy on YouTube do, where the end of the bar is rounded, and the face of the mortise is curved to match. So that when it tensions, and the end bars angle, it simply rotates the two curves on each other. A cleaner look than with straight bars, where the angling would leave gaps.
THAT was fun to figure out the geometry on, and then cut in… Oi.
I didn’t get them perfect, but they’re pretty dang good, if I do say so myself.