March 20, 201214 yr  Glue up has cured out.   Time to get busy.   Checked for nails in the pattern area..... #$#$#@##!! two old cut nails!   Flip blank over, redraw pattern in a NAIL-FREE area.   Next, cutting this handle out. Ok, let's see. I have an old sabresaw, a clamp, a back porch WITH a 2x4 railing, a "e" cord back into the house,  a nice warm sunny morning and a new blade in the saw.   Sounds like a plan, right?  Took two cuts to do this first cutout.   Cut was started using a "plunge cut".    Once the blade sawed it's way through, it was off to the races!    Then the waste fell out, into the yard below.  OK, reset clamp, we are going to the outside.    That took awhile, several different cuts.   Start "here" for a bit, start over "there" to meet up with the first, and so on around the "block".   Finally, I was left holding the blank:I have no idea WHAT type of hardwood this is, but it do stink!   Next up?   Shape, sand, saw kerf, sand, drill for sawnuts ( and a MEDALLION) sand..... did I mention sand?   Once all of that is done, I just MIGHT have a nice 8 point cross-cut saw, to go with the D8.   This might be fun, afterall.... 'and may the road raise up to meet ye'
March 20, 201214 yr Author  Took this rough (VERY ROUGH) blank downstairs to the "Sanding Center".     Smoothed out the curves and some of the flat areas.  Brought it back upstairs and laid the old "Pattern" handle on the new handle.    Used a drill bit to just mark the sawnut hole locations on the new handle.    Just a mark, that is all.    Used these marks to locate the saw blade locations.    I was trying to locate where the kerf will go.   It will take two cuts to get the kerf just right. A "main" cut at one angle, a second cut will have a different angle.    Need to schedule some router time, next.     Much easier with the router doing the round-over work, than using a bunch of files and rasps.  'and may the road raise up to meet ye'
March 22, 201214 yr Author  Still not sure WHAT wood i have here.    Some ways, looks like an oak.    Other ways, like a maple of some sort.    Not hard enough to be a Hickory, although they are all over the area, mainly Shagbark hickory.  The nails still in the blank aren't blackened like an Oak would turn them.     Just a thin black line around the nail.  These boards were wet, at one time, too.  Drying out a little "cracky" now.    That big old knot in the blank doesn't look like the ones I've seen in other oaks.   Mystery Wood?  Or, a resource wood???? 'and may the road raise up to meet ye'
March 22, 201214 yr Author  Seems the wood is either a Sycamore, or a Beech.    Grain has brown , square "ray flakes" in the edge grain.    This might turn out GOOD! 'and may the road raise up to meet ye'
March 23, 201214 yr Author  Got to the shop tonight. Turned on the router table to roundover the handle... Brought along my D8, to cut the kerf in the handle, as well.     Rounded over all the edges.  A few burn marks, nothing that can't be sanded away.   D8 cut the kerf like sawing butter, may not have to sharpen the D8 afterall.   Got the blade to fit in it's new home, and drill the sawnut holes all the way through.   Hey, it FITShandplaned all the layout lines off, don't need them anymore.   Handle seems to fit my hand quite nicely, although I still have a lot of sanding to do.  Another look: I also took the blade back out, clamped it up in a makeshift saw vise. I had a extra slim taper file.   Three strokes, straight across each tooth.   I come back later, after the sawnuts are in, to check how this thing saws.   $2 saw, free wood, a little time...... 'and may the road raise up to meet ye'
March 23, 201214 yr Steven, Your having way to much fun for a $2.00 investment! Looking Good! Larry OWWM Forum Host
March 23, 201214 yr Lookin good man! Looks like it was made for it! Finish?John MorrisThe Patriot WoodworkerProud Supporter of Wounded Warrior Project and Homes For Our Troops
March 23, 201214 yr Author Finish will be a coat of Ipswich Pine, and a coat of poly.   KISS is the rule in this shop.   I use what I have on hand....John Morris said: Lookin good man! Looks like it was made for it! Finish? John MorrisThe Patriot WoodworkerProud Supporter of Wounded Warrior Project and Homes For Our Troops
March 23, 201214 yr Author Went downtown, had to mail out some tote for a friend.   Picked up two saws for $5 + TAX  Word must be getting out about the local Rust Hunter.   One saw will be a straight clean up and done, a Disston R1  "rancher".     The other saw?     A no-name ( not even an etch) saw, that supplied the missing sawnuts for the 8 point saw.    Got those installed, and tried out the "new" saw.    NOT bad, not bad at all.  Pictures to come later.... 'and may the road raise up to meet ye'
March 23, 201214 yr Very nice work Steve. You made it look better than the original did.John MoodySite AdministratorJohn Moody Woodworkshttp://www.johnmoodywoodworks.com
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