Disston No. 7 Refurbish

This is number 2 of 2 posts about two saws I just refurbished. The other is a Carcase Saw. I've had this saw for a little while and wanted to fix it up. I wasn't sure it was a number 7 until I cleaned the plate, but I guess I'm getting ahead of myself. It was clear from the medallion that I had a Disston from 1896 to 1917, and the tote looked like the No. 7 design, but it was chipped in two places. The upper horn was missing a chunk, and one side of the lambs tongue was gone.

The tote after I removed it and cleaned it with denatured alcohol

So I pulled the saw apart and set the plate in vinegar to loosen the surface rust. You can read more about that process on the carcase saw refurbish. The tricky part of this refurbish was the tote. The chip at the upper horn left a lot of wood at upper part of the horn, and I wanted to keep as much as I could, so I clamped it up in a hand screw clamp and cut out the damage with my small backsaw. I used a small try square to keep thecuts straight. Then I used a chisel to square up the notch for the patch.

The try square held tight to the hand clamp acts as a cutting guide

For the lambs tongue, I used the chisel to flatten the area, and then glued in a small piece of quartersawn beech in both places, doing my best to align the grain. I set up a series of small bar clamps and rubber bands to hold the little patches in place. The rubber bands are great because you can wrap them around the patch to apply pressure from a variety of angles.

The rough cut horn patch

Once the glue dried on the patches, I cut them roughly to follow the shape I was looking for and then went to work with a chisel, and then some rasps and files to clean up the shape, trying not to remove any of the existing wood in the process.

The rough cut lambs tongue patch

The lambs tongue ready for sanding and toning

The horn patch ready for sanding and finish, note the contrast in color

Touching up the color of the patches was next, so I tried a darkening agent first; vinegar mixed with steel, which reacts with the tannins in the wood to darken the surface. Once that dried I touched it up with some sandpaper and  rubbed the entire with raw linseed oil. A short time later I wiped off the excess, and set it aside to dry. In hindsight, I wish I'd adjusted the color better before putting on the linseed oil, but I couldn't see how poorly the color matched until the oil was on there; that made the next step difficult. I tried some wood stain to darken up the patches some more, which I let set and then rubbed off. The linseed oil kept the stain from penetrating, and while the lambs tongue turned out nice, the horn patch is not dark enough.

Steel and vinegar solution after a few minutes

After the solution dries, a light sanding evens out the tone

While the linseed oil dried, I turned my attention back to the plate. My one piece of advice, don't go too heavy with the sandpaper grit, its hard to get the scratches out later. Okay, one more nugget; keep the sanding strokes long and straight, they show when you're done, and short, wavy strokes look wrong. After a dip in the vinegar and some cleaning and light sanding the plate looked pretty good, so I put some paste wax on it and set it aside.

The etch confirms its a no. 7, early 1900s

I put a few coats of shellac on the tote, sanding lightly between coats. When it was good and hard, I rubbed some paste wax with a fine steel wool to take down some of the sheen and add some protection. The saw bolts and medallion I cleaned just a little with a Scotch Bright pad; I like to see some of that old color on the brass. The fleck in this quarter-sawn beech is beautiful.

The finished tote. The lambs tongue looks like it grew there

The refurbished Disston No. 7

All in all this was a fun project, and the two saws that I ended up with look great and are ready to go back to work. I guess I'll have to put them in the next rotation for a little tune-up sharpening!

Carcase Saw Refurbish

This is 1 of 2 posts on saw refurbishing I just did. I also cleaned up a nice Disston No. 7 I've had around for a while, and this saw, a reasonably new purchase for me. I was looking for a carcase saw that was a little bigger, and not quite as heavy as the W. Tyzack, Sons & Turner saw I fixed up last summer. This saw has a 14-inch by 3-inch plate, 13 PPI, crosscut.

Looks like a beater, but there's potential there

This Jackson is probably a little older than the Tyzack, but new enough that all of the detail had been designed out of the tote, similar to the Tyzack. It also doesn't have a Disston medallion, so I'm not sure when it was made, but I'm guessing something after 1950.

A little worn, a little rusty, a small chip in the chamfer, and no style

The plate was in good shape and the tote was solid, with just a small amount of play where it was mounted to the plate. And the tote? Its just ugly. All curves and no angles. No balance.

The tote after cleaning with denatured alcohol, with the inspiration tote

So I pulled it apart, and soaked the plate for a short while in white vinegar. I know, folks say that ascorbic acid (vitamin C) is supposed to be better, or some commercial rust remover that I can't afford, but the vinegar worked good for me. After just a day, I pulled the plate out and scrubbed it with hot water and soap to remove the vinegar, the carbon left on the steel, and whatever general crud was left on there. Then it was wire brushing and the scotch bright pad to clean up the metal.

I'm not trying to make the tote look new. I like the age, it tells a story

The tote I repaired by cleaning off the broken chamfer square and gluing in a small piece of beech with the grain aligned. Once that was dry, I shaped it to match the opposite side with a chisel and then re-shaped tote, adding back the V-notch, a double nib ahead of the top horn, and I sharpened up the notch ahead of the bottom horn. The changes are subtle, but the make a difference. I cut the shape with the band saw and some files, and then cleaned it up with some finer files and then sandpaper.

After the vinegar bath, a good wash, and dry scrub with a Scotch Bright pad

Once the re-shaping was done, I gave the tote another light sanding. I'm not trying to remove all of the marks, dings and scars, just most of the dirt, paint drops, and the crud. It tends to build up in the shellac as it gets damp and sticky over the years. Its hard to see, but just before finishing, I added an extra chamfer stop to each cheek. It looks like there might have been a very small one there, so I deepened them.

Click on the picture for a blow-up. The grain in this quarter-sawn beech is nice

When it was clean, I rubbed some raw linseed oil into the tote, to protect it, bring out the grain, and to swell the wood up a little. I think the dried out wood was part of the reason for the loose fit on the plate. If its still loose when I put it back on, I figured I'd file a little bit off of the bolts to keep them from bottoming out in the nuts, but it worked out fine and I didn't have to do that.

The refurbished carcase saw

The next day, while the linseed oil was still uncured, I wiped off the excess and put on a coat of 2# cut shellac and left it to dry overnight. The shellac gets mixed up with the oil on the surface, and the next day the shellac is still a little sticky, and even oily in some places. I sanded off any high points and put another coat of shellac on, which dried up fine. The linseed oil and shellac mix make a kind of varnish (this is what I tell myself anyway) which I think helps to binds the shellac to the wood, and slows the drying of the linseed oil. Time will tell, but I think it may work out to be pretty good.

Before re-assembly, I touched up the saw bolts and medallion with the Scotch Bight pad, but didn't remove all of the color. The bright brass is pretty, but too pretty for a saw that looks its age. I put paste wax on the tote and on the plate to protect them. I used a fine steel wool which takes some of the shine off of the shellac so its a little more matte, which looks good.

I haven't even sharpened this saw. It cuts great. Now it looks great, won't rust anymore and the tote doesn't wiggle. That's worth a few hours, and I did the Disston No. 7 at the same time, so... efficiency, baby.

Hand Tools

Hand Tools: Their Ways and Workings is a beautiful soft cover book written and illustrated by Aldren A. Watson in 1982. This is now my go-to guide for hand tools. Watson is clearly a lifelong user and fan of hand tools and in this book he has poured out all of what he knows, illustrated clearly and concisely with beautiful hand-drawn illustrations of the tools, their parts, their use, and even care and sharpening. The appendixes even include measured drawings and instructions for building your own jigs, wooden hand tools, a work bench (including a version that folds up in a closet for the apartment dwellers) and patterns for replacement handles.

Exploded view of a smoothing plane

The book is organized by tool types. Each tool is described in detail, with cut away drawings of the innards, and its workings so the tool owner fully understands the tool and how it functions. Watson explains, and often illustrates the variations found in the tool, what the different options and adjustments are good for and then goes on to describe how the tool is used. These descriptions are full of examples, and advice ton the best ways to work, often with illustrated techniques, tips, and time savers along the way. For example, in the discussion about a spirit level there is a great tip for leveling a wooden table that doesn't include cutting the legs or using a matchbook. Fantastic!

Do you know this is called an adze-eye hammer?

If you are just starting out with woodworking tools, or if you've been using them for years, like I have, this book has something (many things!) for you. If you've been outfitting your shop with the latest power tools you see on The New Yankee Workshop and shows like it, you may want to take look at this book and see what hand tools can do, often times with less effort, less set-up time, less sawdust, and better results.

Knowing what's inside informs its proper use

Aldren Watson was a professional illustrator, woodworker, print maker and book binder. He died just a little while ago, in 2013 at 95.

Read this book. And then set it in your workshop for reference.


I also posted this book review on my other blog.