1.0 Materials and Supplies
1.1 Soft face hammer, 24-48 oz
1.2 Two blocks of soft wood approximately 1.5” X 0.75” X 4”
1.3 Lithium grease, Permatex #80345 or equivalent
1.4 Assortment of sand paper up to 400 grit.
NOTE: It is not absolutely necessary to use grease, but it does make the job easier and does not seem to adversely affect the stability of the back/plate assembly.
1.5 Saw blade/plate 0.015” to 0.0.035” thick
1.6 Alamo Toolworks saw back
1.7 Machinists/Mechanics vise (Improtant: The vise jaws must be perfectly parallel and close uniformly across their width otherwise the saw plate will wrinkle!)
1.8 Arbor press (optional)
1.9 Hand sanding block.
Figure 1. Soft face hammer and vise
Figure 2. Two blocks of soft pine
Figure 3. Permatex lithium grease
2.1 Tempered and polished spring steel in the raw state is often sufficiently smooth to proceed directly to back installation. If you have taper ground or otherwise roughened the surface of the saw plate or if it is rusted you need to smooth the saw plate before installing the back. Failure to smooth a rough plate will likely result in the back being bent during installation.
2.2 Prepare the surface of the saw plate by sanding it using silicon carbide sand paper up through at least 280 grit. Sanding through 400 grit or higher is preferred..
2.3 Prepare your vise such that it is locked in a position that will allow you to comfortably drive the saw back onto the plate
2.4 Place your saw plate between the two blocks of wood with about 0.75” of saw plate protruding above the top surfaces of the wooden blocks. Secure the blocks and plate in your vise. Note, for heavier or longer backs it may be necessary to clamp the saw plate directly with the vise jaws. Be sure to use a vise with plenty of holding power. If you clamp the plate with the vise jaws make sure that the jaws do not mark or distort the plate. Wilton brand vises have very small teeth that don’t indent the saw plate. Otherwise, turn your vise jaws around such that the smooth faces grip the plate. In the alternative use two pieces of sheet metal as sacrificial vise jaws to avoid damaging your saw plate.
2.5 Apply a small amount of lithium grease down both sides of the saw plate, see Figure 4.
Figure 4. Grease the saw plate
2.6 Start the saw back down the plate by inserting the corner of the plate into the opening at either end of the saw back. See Figure 5.
Figure 5. Start the back onto the saw plate.
2.7 GENTLY tap the saw back onto the plate by lightly driving the back using the soft-face hammer as if you were driving a nail. See Figure 6.
Figure 6. Gently start the back down the plate.
2.8 STABILIZE the saw back with your off-hand while you tap the back down the saw plate, see Figure 7.
Figure 7. Stabilize the back with your off hand.
2.9 Continue tapping the back down the saw plate.
Figure 8. Almost there!
2.10 Drive the back down the plate until the toe of the back is in the desired position relative to the plate.
Figure 9. Back in position.
2.11 You may now adjust the position of the back on the plate by gently tapping uniformly down the length of the plate with the hammer to adjust the back position on the plate
Figure 10. Adjust back position on the saw plate.
2.12 Viola! You’ve done it! Congratulations!
Figure 11. Completed assembly
2.13 Finally, adjust the back/plate assembly for straightness. You can flex the assembly gently by hand or use an arbor press as below.
Now you make or install your preferred handle, finish and use your saw.
Thanks again for your purchase,
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