1.0 Materials Supplies and Tools needed
2.1 First and foremost be safe, wear and consistently use all appropriate personal
2.1 Lay out the components of you ATW Pattern Makers Saw kit and all needed tools and supplies as described in Section 1 above.
2.3 Handle shaping can be accomplished in a variety of ways using a wide variety of tools.
From the left is a dovetail saw, 15 ppi having a 0.015” thick saw plate. Next to that is an ATW Gentlemans saw 16 ppi also with a 0.015” saw plate. Next is a variety of Nicholson files including a 14” rat tail bastard cut, a 10” Superior milled tooth, a 10” rat tail smooth cut, a 8” knife profile x smooth cut and a 8” square profile smooth cut. The rasps are all from Liogier and include an 11 gr. 10” cabinet maker’s rasp, a 12 gr. rat tail, a 14 gr model makers rasp and Handle Makers Rasps in 9, 12 and 15 gr.
You do not need all of these tools, a simple round file will work but you work will go faster and the results will be better if you use better tools.
2.4 The first step is the preparation of the slot in the handle for the blade. First lay your handle on top of the blade and trace the outline of the blade onto the handle to give you an idea of where and how deep to make the blade slot. Don’t forget to mark the points where you want your rivets. Adjust the relative positions of the blade and handle to suit your preference for hang angle.
2.5 Now you must accurately mark the position of the blade slot. It is best to do this operation using a marking gauge having a cutting wheel such as the Bridge City Toolworks. Use a piece of leather to protect your handle from the vise jaws.
Use of a marking gauge is not essential; you can simply mark the center line with a pencil. Using a marking gauge with a cutting wheel will however create an initial scribed line that will allow you to more easily position your saw for making the blade slot.
Bring the scribed line around the cheeks of the saw handle until it intersects with the blade outline you penciled in as described above.
2.6 Now begin cutting the blade slot. Start slowly and carefully and cut a shallow groove from one end of the blade slot to the other following the cut made by the marking gauge. Make sure you slot is straight from the start!
2.7 Deepen the blade slot until you have spanned the section of wood between the beginning and the ending marks made on the handle.
To be continued in Part II...
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