I derive much satisfaction from designing and making new (and new to me) tools. Whether it is an original design or a reproduction of an old one, the process of creating that first working model is always a rush.
For some time now, I have wanted to offer an open handled carcase saw. But rather than simply fitting an open handle on my Disston pattern carcase saw, I wanted to make a saw that had some real differences. When I was asked to make a version of the 12″ carcase saw in Smith’s Key, I jumped at the chance. I had never made a saw with a tapered spine, and the dramatically canted blade was also a first. While the saw presented no technical challenges, I looked forward to testing it.
The saw did not disappoint. While I cannot say that I prefer the design over my Disston-based carcase saw, its distinctive feel more than stood its ground. While the Disston pattern carcase saw feels like driving a Cadillac, the Smith’s Key saw feels like being behind the wheel of a Porsche. Or at least what I imagine that would feel like, since I have never had the pleasure of joyriding in a Porsche.
Knowing that the tapered spine and canted blade worked so well, I decided to take the plunge and come up with my own version of the carcase saw in Smith’s Key.
When I draw up a saw handle for my use, I begin by importing one or more pictures of saws and handles into AutoCAD (I do all of my drawing in that program). Using various features for reference, I scale the picture(s) to full size, then pull out the elements I want to keep, whether they be from one or multiple saws, and add my own touches. Pulling these elements together is a process of moving, stretching, joining, and fairing the lines until they form a pleasing shape that is properly proportioned.
When I am done, I have a template for the first prototype. If this works, I go back and resize the handle for different hands. Parts of the handle can simply be scaled up or down, but much of it needs a little tweaking to look right.
For the first saw, I have the perfect piece of wood – a small piece of elm from my parents’ property that has been air drying since I cut it two years ago. I have never worked this wood before, but the quartersawn figure looks promising.
My take on Smith’s Key 12″ carcase saw.
Specifications for the saw:
- 12″ long at the toothline
- 2 3/8″ depth of cut at the toe; 2 7/8″ depth of cut near the heel
- Tapered spine
All of the options that are found on my other saws will also be available on this saw.
I do not have a good estimate of when these will be available on my website, but it will most likely be a few months yet.
