Hand Tools

Subject:
Re: Handle shaping method and tools... *LINK*
Response To:
Re: A small experiment ()

John Aniano in Central NJ
Wiley,

You asked about tools/methods for shaping plane totes. Below is a description of the method I've used to make QS beech saw handles.

First, cut to the exact line of the pattern. Don't aim wide and then say "I'll just take it down later". Cut to the line!!! The mantra "craftsmanship of risk", or something like that. I prefer my Jet Scroll saw, on slow speed with an agressive as possible blade installed. It will take a while. Just let the blade cut and don't force it. I've used the Flying Dutchman blades and they work well.

FWIW, if I can, I use chisels and knives to cut the shaping bevels as aggressively and as quickly as possible. Use whatever works. In the tightly curved concave sections, I've used coarse and fine rasps, using a side/skating motion. Not straight along the length of the rasp, but instead pushing it sideways while going forward. One of the Ariou modelmakers rasps is my favorite. On the convex portions, I prefer the flat side of a narrow rasp, again moving sideways as well as forward. I am right handed and these are right handed stitched rasps and files.

My comments about the bevels themselves - make them beautiful. Make them even, flowing, smooth. All else in the flow of the handle will arise from these bevels. Make them as good as possible.

After creating the bevels, usually five along the whole contour, break the corners off with a rasp. Then, with 80 grit cloth backed sandpaper strips, do the shoe-shine method to fully round the edges. If the sandpaper gets worn, get new strips! Use the cloth backed abrasive as a cutting tool. Move up to 120 grit cloth strips and maybe 240 grit. Then it is basically done. Just need to lightly plane and sand the sides to get that crisp line between the handle sides and the contour.

My method is based on Isaac Smith's excellent blog on saw making. Somewhat the same, but somewhat different.

Over and out,

John

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Re: A small experiment
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