Easier way to do this sawback?

[Daniel Koster]

This is a picture of a sawback I have made:



I did it by hand...with a triangle file.

It doesn't look that bad...but.....the finish is not what I had hoped for and it is a tedious and grueling task! (not to mention painful)

So, does anybody know of a jig....a tool....a grinding wheel....something that might speed this along and make it more precise?

I have access to a mill, if that helps.

Thanks for any suggestions!



p.s. fwiw, this is a larger version of the sawblade on my Swiss Army Knife.

[B.Finnigan]

On that tooth configuration there probably is a faster way but nothing comes to mind right now. I have made a few hidden tang sloting saws but I cut all the teeth by hand on non annealed 1095(PITA!!!). A finish file will clean up the cuts and it will be alot faster then the primary cuts were. Simonds makes a great finish file that leaves a very neat satin finish that really does not need any further clean up. You can also use a triangle EDM stone to clean it up. They go up to 800-1000 grit depending on which abrasive you want.

The teeth look very cool even with the first cut marks. If it is any consolation the tang saws were just bit over 4" long and each one took 2 to 2 1/2 hrs to hand cut. That was with a jig which did not speed it up but kept the tooth pitch even.

Don't give up, just keep filing!

[Daniel Koster]

sounds interesting....

where can I get an EDM stone? and a Simmonds finishing file?

Thanks!

[B.Finnigan]

I get my Simonds files locally but if you did a Google search you will find some online retailers. EDM stones can be purchasd anywhere machining supplies/equipment is sold. There is a guy on Ebay that carries the boride EDM stones. He may have some triangle stones.