Japanese Handsaws: The Mystery of the Burnt Blade

Everything in life is risk, from the minute you wake up in the morning and stick your tongue into a toaster.

Anon

Introduction

In this article your most humble and obedient servant will present a little-known mystery about traditional Japanese handsaws I call the “Mystery of the Burnt Blade,” as well as a related psychedelic conundrum called “Black Light!”

I will also provide a brief description of how one of the last sawsmiths in the world hand-forges his custom handsaws, and explain how these two mysteries are linked to this ancient, even magical, process.

If you have a metallurgical psychologist’s hat, as I do, perhaps one made of aluminum foil or even brass with attached wires, bells or baubles, now is the time to secure it to your seat of knowledge.

Mysteries

Over the years Gentle Reader and your most humble and obedient servant have grappled with several tool-related enigmas, including such notable head scratchers as: “The Mystery of Steel,” “The Mystery of the Brittle Blade,” and “The Mystery of the Scratched Blade.” You may recall that once we even crossed the center median and swerved drunkenly into the path of an esoteric conundrum called “Supernatural Bevel Angles.” Yeeehaw! That was a close one!

In a world boiling-over with mysteries, however, prioritizing them is sometimes vexingly difficult. For example, is the “Meaning of Life” more important than “Were Bert and Ernie in Love?” Or is the question “When will the Entwives return from shopping at the mall?” weightier than “Are the four surviving Nazgul running just Shat Fransisco or all of Calipornia?”

Cogitating such mysteries has worn my thinking cap down to just a button and a bit of lint, but before I forget (I’m supposed to take some bitter little green pills for my memory, but keep forgetting) I would like to submit for your kind consideration a little-known mystery about traditional Japanese handsaws. As mysteries go, it’s nowhere near as high on the priority list as the whereabouts of the missing Nazguls but nonetheless it still puzzles many. Being exceptionally perspicacious, Gentle Reader may find a worthwhile gem or two hidden among the rubble in this article.

And the story goes something like this.

The Story

The curtain on this mystery doesn’t open on a moonless night, black and ragged as a Chicago politician’s soul, concealing a MacBethan circle of wart-covered witches chanting incantations while stirring a cauldron bubbling over purple flames.

Nor is the scene of this mystery a locked cell in a curiously vacated wing of Gotham’s Metropolitan Correctional Center where the guardsmen all nap cherubically, and security cameras all malfunction magically (perhaps due to a “Nox” spell?), and where a millionaire child nookie bookie has shuffled off his mortal coil by hanging himself with a bedsheet after breaking his own neck. Harry Houdini must be proud!

No, the curtain on this mystery opens of an early evening in Tokyo almost 40 years ago in front of a rickety old wooden building facing a busy street erected in the warm ashes produced by 174 B-29s on the nights of March 9th and 10th 1945 when the city and many souls burned brightly.

Gentle Reader, we find ourselves in front of the shop and residence of a small, pipe-smoking saw sharpener and his family. They live on its second floor, with a workshop on the ground floor adjoining a dirt-floored doma with a single rickety sliding door opening to the street. There’s space in the poorly lighted entry for perhaps three people who don’t despise each other to stand, but no more. The shop space doesn’t have shelves or glass cases, just teetering stacks of newspapers and magazines wrapped in twine crowding in from the walls. The place feels strange and smells of oil and steel filings. I don’t know about you, but it’s an atmosphere I love.

Prior to that time my experience with Japanese handsaws was limited to inexpensive hardware store products with bright shiny blades. I didn’t know much about who made them or how they were made, but they seemed to work OK. On the day of this mystery I was looking for a more specialized saw for ripping 6X6 timbers, one not sold by the average hardware store, so I visited the shop of this professional saw sharpener.

As I opened the rickety wood and glass sliding door and called a greeting the little saw sharpener came out from the back, kneeled seiza-style on the raised floor of his workspace, and smiled like a wood carving of a buddhist saint.

After introductions, I described the job I needed to do, the type of wood I had to cut, and the type of saw I thought would work best. He made a thoughtful face as he sorted through his stock of saws in his mind, bobbed his head decisively once, stood up, and without saying a word went into the back. He returned with a saw blade wrapped in newspaper.

When I unwrapped the blade (no handle) my heart sang as I gazed upon its unadorned, elegant lines and subtle beauty. I could feel the blade quivering with excitement at the prospect of being fed some yummy wood after a boring confinement in the back. It was a 300mm single-edged kataba rip saw with the brand “Nakaya Genji” chiseled into the steel blade.

The saw sharpener told me it was made in Tokyo (yes there were still many sawsmiths living and working in Tokyo back then) by a reputable and skilled blacksmith, but not a famous one, that it was a hand-forged, top-quality working tool, one he had sharpened himself, and that he thought it would satisfy my requirements.

The only problem was cost, about twice what I had budgeted, but pretending I knew what I was doing, I flexed the blade, held it up to the dim light to check the plate for untoward distortions, and the teeth for cavities. I even pressed my palm against them to check their sharpness. After all this posturing I agreed with the saw sharpener that it was a fine blade. With one reservation….

Mysterious Colors

A hozohiki rip saw hand-forged many years ago by Takijiro for your YMHOS

Now, at the time of my visit to the little saw sharpener’s curious shop I didn’t have enough experience or specialized knowledge to ask intelligent questions about the steel and techniques used to forge and tooth the saw, but although I was ignorant, my eyeballs were still not “fushiana” (“knot holes 節穴”), as the saying goes in Japanese, for they noticed something that wasn’t quite right.

What was this smudge on the saw’s face that shocked me but did not faze a professional saw sharpener? It was a localized discoloration at the center of the blade, a vaguely-shaped area golden brown in color, possibly indicative of the blade having been exposed to high temperatures, perhaps hot enough to soften the steel, a serious defect indeed in the case of chisel and plane blades.

The saw sharpener was not impressed in the least with what my knotholes had revealed, but exercising extreme patience, gave me a partial explanation.

As he clarified at the time, and as I was able to confirm in more detail during the intervening years, this area of color is commonly seen on the plates of quality saws made in Western Japan, which included Tokyo where I purchased the saw in question, but it is not commonly seen on saws made in Eastern Japan, which have simple bright steel blades instead. Likewise, inexpensive, mass-produced handsaws, including exchangeable-blade kaeba saws, never have this colorization. Ahah! The thot plickened.

C&S Tools’ hozohiki rip saw hand-forged by Nakaya Takijiro. Please notice the colorization.
C&S Tools’ dozuki crosscut saw hand-forged by Nakaya Takijiro. Please notice the colorization.

So what I deduced from his comment was that this spot of color is neither strange nor suspicious, but is actually desireable, indeed seen as an indicator of quality, depending upon geography. Sound hinky to you? It did to me too.

An Historical Example

Years ago the following example was related to me by a reliable source with personal knowledge, and I while I am extremely fond of daring fashion statements, I have not seen it with my own knotholes and so won’t accept any bets about its veracity that involve a forfeit of wearing lady’s underwear on my head out in public again, so please don’t offer.

From 1639 to 1834 Japan was closed to foreign countries with the sole exception of Holland, and even then access was severely limited.

In the early 1800’s a Dutch doctor purchased a bunch of Japanese woodworking tools which he took back to Holland. Those tools recently returned to Japan and observers noted they had the same appearance as modern handsaws saws made in Eastern Japan, evidence that this colorization is not just a modern feature of Japanese handsaws.

How to Make a Traditional Japanese Handsaw

In order to explain the metallurgical roots of the Mystery of the Burnt Blade I humbly beg Gentle Reader’s kind indulgence as I relate the following summary of the process of making a hand-forged professional-grade handsaw in Eastern Japan as explained to me by Nakaya Takijiro Masayoshi, one for the few remaining master sawsmiths in the world. Any errors are the sole responsibility of your smelly groveling servant.

Takijiro posing in front of his forge.
Takijiro applying a final polish to your humble servants bukkiri gagari saw. Two of his anvils are visible. Please notice the scraper marks and colorization of the blade

Steel Selection

Saw blades do not require high levels of carbon. Indeed, too much will make the teeth fragile. Shirogami Saw steel and Shirogami No.2 steel have been popular for many years, and Takijiro uses S-2, but he prefers Yellow Paper steel with its lower amount of carbon for the extra toughness it affords.

With materials now in hand, let’s get to smithing.

Cutting the Plate

The sawsmith first cuts the steel plates for a run of saws using manual shears. These are not embroidery shears held in one hand, but rather a hand-powered mechanism that sits on the floor with a long blade and plenty of leverage.

Initial Forging

Using a gas/charcoal forge, springhammer, hand hammers, and rectangular steel anvil he then heats and shapes the plates.

At the conclusion of this stage the saw plate is an approximately saw shaped piece of thin steel, burnt in appearance and warped. The iron tang will be attached later by forge-welding.

Nakaya Takijiro forging a saw tang
Nakaya Takijiro’s forge set into the floor of his smithy.

Annealing/Normalization

The next step is to anneal the saw plate. Sometimes this process is called “normalizing.” While it involves heating and cooling the blade, instead of making the steel hard, it makes the steel as soft as possible.

The purpose of this step is to relieve stresses, create a uniform and relaxed crystalline structure in the steel, and to soften the steel to prevent cracking during forging.

Annealing and normalization are very similar processes, both performed by heating the steel to a specific “recrystallization” temperature”(about 750˚C or 1380˚F for Shirogami No. 2), and allowing it to “soak” at that temperature for a specific amount of time. In the case of annealing, the steel is left in an oven and the temperature is slowly reduced in accordance with a specific heat curve, but in the case of normalization, the white-hot steel is removed from the forge/oven and allowed to cool at room temperature, a faster, more economical process.

The traditional Japanese annealing/normalization process Takijiro employs at this stage is technically not pure annealing, but neither is it simple normalization. He heats the blades and upon removing them from the forge immediately places them to soak and slowly cool overnight inside a sealed, but neither airtight nor temperature-controlled, container filled with rice straw ashes, a low-oxygen, high-carbon atmosphere.

This annealing/normalization process is hot and dirty work, unsuited to either the impatient factory worker or to mass-production, one that it adds considerable time and cost to production while yielding few benefits purchasers nowadays can discern using Mark-1 Eyeball, as seen through the lens of what I call “Chinese Logic.

Why Chinese logic, you say? Because the benefits it imparts to the crystalline structure of a steel blade are not only impossible to analyze without using an expensive SEM, but are difficult to check through conventional non-destructive quality control procedures, and impossible to observe in an illustration in a catalog (harking back to the Sears Catalog days) or a digital photo on the internet, all reasons why this critical step is always neglected by other than well-trained, dedicated craftsmen like the blacksmiths C&S Tools works with, who refuse to cut corners.

The next morning, the blades are removed from the container. They are still too hot to handle without gloves or tongs.

Cold-forging

Now that the saw plates are roughly shaped and annealed, the next step is to further refine their crystalline structure by forging them using hammer, tongs and anvil. He does not, however, heat the blades during this step.

At this stage Takijiro prefers to forge blades two at a time, one stacked on top of the other. The position of the blades in the stack is changed frequently so approximately the same number of blows directly strike both faces of both blades. Not only does this save time, but it cushions and better distributes the force of the hammer blows.

He then repeats this process by hammering both sides of a single blade.

The purpose of all this violence is to “tighten up” (shimeru 締める) and improve the crystalline structure of the steel.

Obviously, if this step is performed carelessly or without properly annealing the blades beforehand, they will crack sure as eggses is eggses. Just another of those jobs not suited to the amateur.

Quenching

The purpose of quenching the blade, of course, is to create a rigid, hard, even brittle crystalline structure in the steel.

Quenching Step 1: Heat the blade in a gas/charcoal fire to 800 degrees beginning at the tang end of the blade.

Quenching Step 2: When the blade is properly heated, as judged by eye, plunge it it into rapeseed oil (canola oil is genetically-modified rapeseed oil) cooling it quickly. For more details, please read The Story of a few Steels.

Forge-weld the Tang to the Blade

The next task is to attach the soft iron tang to the hard steel blade by lapping the tang over the blade, heating the lap, and hammering until the two pieces meld. This technique, called “forge welding,” is as old as blacksmithing but has not been standard practice in Japan for the past three or four decades having been entirely replaced by electrical welding.

Takijiro, on the other hand, does not use a welder.

Performance-wise, a forge-welded tang is not superior to an electrically welded one, but since it’s a sure sign of a hand-forged sawblade and indicative of traditional craftsmanship, it’s a detail highly desired by those who know the difference.

A forge-welded tang identified by the curved line crossing the blade just above the “machi” step-down to the tang.

Tempering the Blade

Quenching makes the blade hard, but also brittle and quite useless as-is. The purpose of tempering therefore is to slightly break-down the crystalline structure of the steel while reducing the amount of carbides, thereby making the blade flexible and much tougher.

Proper tempering also greatly improves a blade’s edge-retention performance. This is a key step in the Mystery of Steel, and in the case of Takijiro’s handsaws, is accomplished in four steps.

Tempering Step 1: Heat the blade to 300 °C (570˚F) beginning at the toe (tip) end of the blade, allowing the temperature increase to spread to the tang.

Tempering Step 2: Place the blade on the floor to air-cool.

Tempering Step 3: Reheat the blade to 400˚C (750˚F) beginning at the tang end of the blade, allowing the temperature increase to spread to the toe end.

Tempering Step 4: Place the blade on the floor to air-cool.

The portion of the blade near the forge-welded tang needs to be left a little softer for toughness and to allow the blacksmith to chisel his signature, one reason for the two-step process.

Removing Warpage from the Blade

Subjecting a thin piece of high-carbon steel to extreme violence by fire, hammer, and sudden cooling in oil during the operations described above will always make it warp, so it must next be straightened by the precise use of hammer, tongs and anvil. This is a task that requires patience and much experience.

Adjusting the Thickness and Taper of the Blade.

Two customer ryouba saws, one made in Tokyo and the other Niigata, with handmade handles of larch wood. The colorization is especially dramatic, and although the blacksmiths are different, the color is nearly identical.

The faces of a true high-quality hand-forged saw blade are not tapered willy nilly, nor in the simple flat planes typical of ground and sanded blades. Instead it must be shaped in a “double-taper.” In the case of a kataba (single-edge) saw, the first taper is from the teeth to the blade’s back, meaning the blade is thickest at the teeth, becoming gradually thinner towards the back.

The second taper is the blade becoming thinner from tang to toe.

Combining these two tapers results not in the creation of two flat planes in the saw blade, but curved surfaces on both faces of the sawblade.

Let’s examine this double-tapered surface in a bit more detail. A case in point is the more complicated double-edged ryouba saw. If we examine a cross-sectional cut across a high-quality ryouba sawblade’s width (perpendicular to the long axis of the blade), we will observe that the blade is thinnest at its long center axis and thickens moving outwards towards the teeth on both sides so that, as the blade cuts deeper into the wood, the gap between the blade and hairy sides of the cut increases.

If we next examine a cross-sectional cut through the length of the blade, we will see the plate is thickest at the tang-end and thinnest at the toe, such that as the blade is pulled towards the user, the portion of the blade cutting the kerf is always thinner than the kerf itself, thereby reducing friction and the tendency to bind and buckle. The combination of these two tapers on each face of a sawblade is what your humble servant calls a “double taper.”

Restating the previous paragraph, as result of this double-taper the thickness of the sawblade inside the kerf being cut measurably decreases as a stroke progresses, incrementally reducing the pinching forces acting on the blade in the kerf, as well as the friction acting on the blade produced by hairy fibers. The net result is that the energy necessary to motivate the blade is decreased, cutting precision is improved, and the blade is less likely to be damaged by buckling.

In the case of double-edged ryouba saws, this increase in thickness from the plate’s centerline to the teeth has limited usefulness, however, because, as the blade cuts into the wood deeper than its centerline, the blade gradually becomes thicker increasing friction in the kerf. This is one reason why some craftsmen, including your humble galley slave, prefer single-edged “kataba” saws over the more cost-effective and convenient ryouba saw.

These pinching/ friction forces can also be reduced, of course, by adding extra set to the teeth. But set is not all blue bunnies and fairy farts because, while it’s indeed effective at reducing pinching/friction forces acting on the blade in the direction of the blade’s width, it is not effective in the direction of the blade’s length, unless a large amount of set is added.

Applying minimal set matters because the greater the set, the more wood must be cut, the more time and energy must be expended, and the more cutting precision is impeded. Cheap saws and replaceable-blade saws lacking taper must have a humongous amount of applied set, BTW, an ungainly and wasteful feature despised by knowledgeable craftsmen.

A high-quality handsaw with a good double-taper will cut with less effort, in less time, without binding, and with greater control and precision than a plain, flat saw, even one with adequate set. Contingent, of course, on the skills and perception of the user.

I don’t know where this subtle idea was first developed, but I understand it has been used by advanced blacksmiths throughout the world for centuries. Why? because it works.

So how does the sawsmith impart double taper to a blade? It begins with having a vision of the finished blade in-mind when shaping and forging the blade with fire, hammer and tongs. But there are practical limits to the precision achievable with fire and hammer, so the master sawsmith will adjust the blade’s thickness using two-handed scrapers to shave steel from the plate.

Takijiro’s toolrack of two-handed sen scrapers.
A pile of hardened steel shavings from a saw plate produced by Takijiro’s sen scrapers.

Although few know them and even fewer use them nowadays, scrapers were once tools found in every metal working shop around the world. In trained hands they are capable of achieving amazing precision, such that all metalworkers and even college students studying machinery engineering in the USA as late as the 1960’s were trained extensively in their use.

Expensive 3-axis CNC grinders can do it, but conventional grinding and sanding equipment is unable to achieve the quality of taper that hand-scraping can.

The marks hand scrapers leave on a sawblade are obvious and very different from those left by grinders and sanders, and being the results of handwork, are something to look for when evaluating a saw. On the other hand, ground, sanded and polished blades are shinier and prettier than scraped blades, and if the polishing was done after tapering by hand with a scraper, I can find no fault with it.

But please be aware that extensive sanding and polishing contribute nothing to a saw’s performance, whilw on the other hand are highly effective at concealing grinding failures. Caveat emptor baby.

Cut the Teeth

The sawsmith uses a hand-powered shear contraption with tooth-shaped blades (kinda sorta like the teeth in pinking shears) to cut (or punch) the teeth. The teeth produced during this step are quite rough.

Rough Filing

The sawsmith uses hand files to shape and refine the teeth cut in the previous step.

This first filing operation produces properly-shaped but not perfectly sharpened teeth.

Applying Set

Now that the teeth are properly shaped, the sawsmith applies right-left set to the teeth using an anvil and a special hammer. The following videos YouTube videos show the process, although at a much slower pace than real life.

  • Video 1 鋸のアサリ出し 其の1 準備編
  • Video 2 鋸のアサリ出し其の2 実践編
  • Video 3 鋸のアサリ出し 其の3 最終編

Cutting The Brand Name

The next step in the process is for the sawsmith to use a hammer, anvil and chisel to carve his registered signature into the blade just above the tang, as seen in the photos in this article. This feature was perhaps borrowed from the sword world, but no one knows. In any case, it’s this unique signature and the way it was cut that witnesses the handmade nature of the saw as well as the name of the craftsman that made it.

Sometimes this brand name is easily read, but often the characters are stylized to the point of illegibility. For instance, not only your humble servant, but most Japanese are unable to read even one of the six characters in Takijiro’s signature. “The signature is the signature” he says.

Sharpening

With the teeth shaped and set applied, the teeth are now ready for their final sharpening.

Traditionally, most blacksmiths simplify this step to a quick and dirty sharpening, but for an extra fee, would send the blade to a professional sharpener for a more refined sharpening job called “Honmetate” (hohn/meh/tah/teh 本目立て). Takijiro, however, was trained by his master to a higher level of proficiency, and for the first 3 years of his apprenticeship was tasked with sharpening saws exclusively, skills that are wonderfully obvious in the performance of his saws. All of his saws receive honmetate by him.

I was unable to find a video showing a professional sharpening job on a cabinet-grade saw in-action, only jobs on larger saws, mostly for trimming apple trees. But while the tools and process are much the same, the skill and speed required to sharpen the numerous fine teeth of a dozuki crosscut saw are awe-inspiring.

Video about making a Japanese-style saw vise LINK

The Answer to the Mystery of the Burnt Blade: Colouration (Irozuke 色付け)

In the Japanese language this final step in the saw making process is called “irozuke” (ee/ro/zoo/keh 色付け) which I’ve translated as “colorization.” In the Japanese language this translates directly to “apply color.” It’s also called kesho ( keh/sho) 化粧), which is the same word used for makeup, as in the gunk and powdered pigments women and actors apply to their faces.

In this step, the sawsmith uses a deformed truncated cone, simply a piece of sheet metal bent into a cone with the pointy end cut off and smashed into an oval shape.

He places the wide end of this cone in his forge, or on a gas stove, so the heat will rise and be funneled into an oval shape. He rests the sawblade on the narrower, upper end of the cone so it focuses heat onto a specific area of the blade. When the blade reaches the right temperature, as judged by color changes, he removes the blade and allows it to air-cool.

The answer to the Mystery of the Burnt Blade, therefore, is this “colorization.”

As described above, the first time your humble dogsbody saw a professional-grade handsaw in Tokyo I was shocked at the sight of the golden-brown spot of color on its blade. Since then, I’ve heard many suppositions for its existence, most pungent BS, but the true reasons for this additional step are threefold.

  1. Colorization is the final step in the tempering process, one that slightly softens the steel in a critical spot making the blade tougher. This is one application of “differential hardening” of which blacksmiths are extremely fond, and is important to a saw’s performance.
  2. Second, the resulting differential hardness slightly reduces the blade’s springiness by damping the tendency in a thin hardened-steel plate to develop resonant harmonic vibration, a problem that inflicts many saws. Gentle Reader may have experienced this while using large Western panel saws when the blade tends to vibrate and quickly “waggle” right and left towards the end of the return stroke, movement that is not only distracting but wastes time and can harm precision. This characteristic too is important to those with the skills adequate to tell the difference.
  3. And last, at least in Eastern Japan, colorization is clear evidence that the saw was properly forged without taking any shortcuts, much like an actress will take care in applying her makeup before a performance, except that, unlike bottle and powder makeup, colorization on a sawblade reveals instead of conceals. Oh yes, and it costs a hell of a lot less than Gucci Beauty‘s foundation gunk.
Theatrical makeup tastefully applied to a lady performer at the Beijing Opera. Were a trowel and sandpaper involved or just Photoshop?
Colorization applied to a Japanese Kabuki actor. Obviously a different kind of theater.

The Black Light Mystery

I will conclude by relating another mystery about handsaws Master Nakaya Takijiro shared with me

According to Takijiro, scraping a sawblade by hand can reveal the quality of the forging and heat-treatment of a saw blade in ways no other methodology can, because shavings freshly scraped from an expertly-forged and heat-treated blade will, for a brief few seconds, exhibit a shiny black color, what he calls “black light” (kurobikari 黒光). On the other hand, shavings scraped from an inferior blade will always be plain bright steel.

A grinder is unable to provide this quality insight.

Conclusion

Despite the subject of this article being somewhat obscure, I pray it has has been informative.

Until we meet again, I have the honor to remain,

YMHOS

A cherry blossom lake in Shakujikoen Park in Tokyo

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Relevant Articles

Japanese Exchangeable Blade Handsaws Part 2 – Pros, Cons & User Improvements

If you want to know what a man’s like, take a good look at how he treats his inferiors, not his equals.

J.K. Rowling, Harry Potter and the Goblet of Fire

Introduction

This is the second in a two part series about Japanese exchangeable-blades handsaws (“kaeba saws”).

In Part 1 we examined the history of how these saws came to be, how they are manufactured, and the market forces that made them so popular in Japan and even overseas. In this conclusion we will consider their advantages and disadvantages compared to traditional fixed-blade saws, and explain a few simple techniques Gentle Reader can employ to improve the performance of one variety.

I think all who have used them will agree that exchangeable-blade handsaws (“kaeba saws”) are effective and convenient products. However, Gentle Reader may be pondering, no doubt with exquisite grace and dignity, the question: “Do kaeba handsaws exhibit performance superior to well-made traditional handsaws?” The simple answer is unequivocal: sometimes yes, sometimes no. The Okey Dokey list below summarizes the reasons supporting your humble servant’s decisive answer.

But to avoid too much confusion, let’s briefly review the materials and techniques used in making the kaeba handsaw before attempting to navigate Okey & Dokey.

Review of Materials and Production

You will recall from Part 1 that kaeba saw blades are manufactured in automated CNC production lines using pre-hardened, pre-sanded, sheet steel of uniform thickness purchased from rolling mills. The sawmaker’s machinery cuts out the blade blanks, deburrs them, punches the teeth, shapes and polishes them with automated precision grinders, adds set to the teeth, and sometimes tensions the blades between rollers. The teeth of some blades are also instantaneously induction heat-treated (what some manufacturers call “impulse hardened) producing teeth harder than a sawfile.

Unlike the blades of traditional, high-quality saws, however, kaeba saw blades are not differentially hardened, taper-ground, trued or hammer-tensioned, nor are their teeth professionally sharpened, tuned or quality inspected. And of course, the backs of backsaws like dozuki are not carefully fitted. These are big, decisive differences not apparent to the untrained eye.

So with these physical differences in mind, let us next consider the pros and cons.

The Okey Dokey List

Some Advantages of Kaeba Handsaws Compared to Traditional Handsaws

  1. Lower Initial Cost: The initial cost of kaeba saws is less than traditional hand-forged saws. This is to be expected as they are mass-produced on automated machinery involving zero handwork by craftsmen.
  2. Greater Convenience: Dull or damaged blades can be quickly replaced with new, sharp blades improving convenience and obviating the need to carry entire bulky spare saws, and to have their teeth resharpened.
  3. Greater Durability: Kaeba sawblades with induction-hardened teeth (aka impulse-hardened teeth) are more durable and remain sharper longer than traditional fixed-blade handsaws, especially when cutting EWP (engineered wood products) such as plywood, MDF, OSB, LVL, glulams, etc. which contain hard adhesives and abrasive sandpaper grit. This is not the case for all kaeba sawblades, of course. From the craftsman’s viewpoint, this is perhaps their most significant performance advantage, and is nothing to sneeze at.
  4. Disposable: Like cat litter, plastic beverage bottles, and modern marriage, kaeba saws are a “use and toss” product that need not be repaired, only replaced. Fortunately, unlike marriage and cat depositions, lawyers don’t get involved much.

Disadvantages of Kaeba Handsaws Compared to Traditional Handsaws

  1. Less Economical Long-term: While cheaper when new, and although some kaeba saw blades can be resharpened (except those with induction-hardened teeth), the cost of a new replacement blade is typically more expensive than the direct cost of a professional sharpening job, another profit motive for planned obsolescence
  2. Limited Blade & Tooth Options: While popular blade and tooth shapes/quantities are readily available, the specialist blade shapes/teeth required for woodworking trades and tasks other than carpentry (e.g. luthier, fine interior joinery, kumiko zaiku, large rip and crosscut work, smooth cutting of hard woods, etc.) are simply not available as kaeba saws often leaving craftsmen who rely solely on kaeba saws bereft of adequate tools. Case in point: most kaeba saw blades are designed to cut the varieties of softwood commonly used in housing construction quickly and efficiently but are not well suited to cutting most hardwoods smoothly or precisely. On the other hand, some craftsmen and certainly professional saw sharpeners can readily modify the teeth of a traditional saw to satisfy specific job requirements. Younger craftsmen that grew up using only kaeba saws do not even realize this sad state of affairs. I encourage Gentle Reader to learn how to sharpen your own noble saws.
  3. Unknown Materials & Quality: As mentioned above, kaeba saw blades are made from pre-hardened, pre-sanded sheet steel (chemical content undisclosed) of uniform thickness supplied by rolling mills (nation of origin undisclosed). When your humble servant first inspected a kaeba saw maker’s plant around 2010, they were using high-quality, clearly-identifiable steel of known chemical composition produced by a reputable Swedish mill (specs and QC marks etched on the surface of the steel), but now that kaeba sawmakers have effectively conquered the handsaw market in Japan, the “bait and switch” principles taught by Harvard Business School and exemplified by McDonalds hamburglers have been fully implemented. Not unlike BS, B&S is an extremely profitable business management tool, one considered wise by some short-sighted business executives and those who can’t count past 20 without dropping their pants. Caveat emptor, my dear.
  4. Differential Heat Treatment: Although some Gentle Readers may be unaware of the importance of differential heat treatment in an excellent sawblade, much less the pros and cons thereof, kaeba sawblades lack the advantages of the differentially hardened plate found in quality, traditional Japanese (and Western) handsaws resulting in:
    1. Decreased toughness of the plate
    2. Increased springiness and resonant vibration in-use often harming precision;
  5. Taper Grinding: Being made of uniform-thickness sheet steel, the kaeba sawblade is not taper-ground resulting in:
    1. Increased binding and kinking in use. A kinked sawblade, of course, is irritating and destroys precision. It’s also less than worthless because it interrupts the user’s work as he replaces it, an inconvenience and expense the uninformed user typically blames on himself even though the true culprit is the inferior sawblade.
    2. Greater set is required to avoid binding and kinking, which equates to more energy and time expended to create more sawdust, a positive factor for weight loss, but not so much for efficient work.
    3. Greater tendency of the blade to wander in the cut increasing irritation while reducing precision.
  6. Sketchy/No Hammer Tensioning: Although some kaeba blades are tensioned between steel rollers in the same way circular sawblades are, the tensioned area in kaeba saws is a band across the length of the blade, and not the ideal oval shape sawsmiths typically produce by hand resulting in greater susceptibility to warpage/buckling as the blade heats up in use resulting in increased friction in the cut, reduced work efficiency, increased irritation to the user, and more damaged blades requiring replacement thereby increasing the profits of sawblade manufacturers, distributors and retailers. Another of Baldrick’s cunning plans?
  7. Less Precision: The precision achievable using kaeba backsaws such as dozuki is significantly less than that of high-quality hand-forged traditional dozuki backsaws for the following reasons:
    1. The back may not be straight;
    2. The back is not secured to the blade as securely permitting more slop;
    3. The plate has never been trued and may not track as precisely.
    4. The set of kaeba saw blades is decidedly excessive for precise joinery work.
  8. Rougher Cuts: Kaeba blades typically have greater set compared to traditional sawblades necessitated by their lack of taper grinding, making the saw cut less smoothly. In addition, uneven left-right set often encourages the sawcut to wander into the weeds.
  9. Landfill Stuffing: As mentioned in Advantage 4 above, like cat litter, plastic beverage bottles, and modern marriage, kaeba saws, are “use and toss” products, veritable landfill stuffing in-waiting. I will leave it to Gentle Reader to decide if this is good or not, but I am convinced kaeba saws find the transition from valued tool to rubbish lonely and emotionally damaging, which explains the increased demand for board certified metallurgical psychologists such as ton modeste serviteur.

Only Gentle Reader can answer the question of which type of saw is superior, but despite my sometimes negative observations listed above, I freely admit to liking and using both types in the context of “horses for courses.”

User Improvements to the Kaeba Dozuki Saw

Many moons ago I associated with a group of young, energetic and extremely pragmatic carpenters in Tokyo intent on finding solutions to deficiencies in modern tools anyone could put into effect. For instance, one item they studied to death was how to get the most from synthetic waterstones, a highly-successful bit of research IMHO.

Another tool they researched was the kaeba dozuki. While they didn’t propose any new, earth-shattering innovations, some of their techniques are worth employing.

Improvement No. 1: Side-jointing the Teeth

This first tuning technique is one that works on all handsaws and can especially help your kaeba dozuki saw cut straighter and more precisely, leaving a narrower kerf and smoother surfaces. This is traditionally performed using a file in the case of standard sawblades, but in the case of a kaeba dozuki saw with induction-hardened teeth, we need to use a harder tool and with more precision; Enter the Arkansas stone stage right.

You will need a new kaeba dozuki blade, a hard (not soft), flat Arkansas whetstone (novaculite) dimensioned approximately 8″x3″ (larger is OK but much smaller won’t work well), a piece of white copy paper, a can of light-weight spray lube such as WD-40, CRC5-56 (not PTFE), or brake cleaner, a relatively clean toothbrush, and a clean cotton rag. Please note that India stones, carborundum stones, waterstones, diamond plates won’t get the job done.

  1. Lay the paper down on a flat, stable, wooden board or workbench. Place the sawblade on top.
  2. Give the blade a light spray of lube.
  3. Gingerly place the hard Arkansas stone lengthwise on the blade parallel to the cutting edge, with one end hanging approximately 25mm (1″) off the toe end of the blade, one long edge resting on the blade, and the opposite long edge hanging off the blade about 6mm (1/4″) past teeth.
  4. Without placing any downward pressure on the stone, pull it towards the heel (handle end) of the blade, parallel to the tooth line, in a single smooth stroke until the end of the stone is hanging about 6mm off the heel of the blade. Slow or fast, it makes no difference, but I prefer slow. Just one stroke, mind you. The goal is for the stone to lightly abrade the sides of the tips of the teeth essentially “jointing” and bringing them all into line. In addition, and perhaps more importantly, even if your sawblade has perfectly uniform teeth, kaeba dozuki blades almost always have too much set, which this technique will reduce, improving the smoothness and precision of the cuts it makes.
  5. Turn the sawblade over and repeat steps 1~4. With this the stone will have made a single pass over both sides of the tips of all the blade’s teeth. In the case of blades with induction-hardened teeth, you may need to make 2 passes of the stone per side, but be aware that every pass reduces the useful life of the blade significantly. Also (and this is very important if you value your sanity), be sure to make the same number of strokes in the same manner to both sides of the blade.
  6. Take the blade outside and blast it with your can of spray lube to remove any particles of stone and metal left in the teeth. You may not be able to see this swarth (mixture of stone, steel and lube residue), but it is there, and if not removed, it will dull the blade during the first stroke in wood sure as eggses is eggses.
  7. Use the toothbrush and more spray lube to scrub the teeth to remove any remaining swarth residue.
  8. Spray the blade with lube or brake cleaner from both sides with the teeth pointing downward flushing any remaining swarth out of the teeth.
  9. Wipe the blade with the cotton rag from the blade’s back over its teeth. You don’t want the teeth to cut the cloth, or the cloth to catch on the teeth. If you observe any swarth residue on the cloth, repeat steps 6, 7 & 8. Do not use the saw until all the swarth is gone.

Tasting the Pudding

Now that the sawblade’s teeth have been side jointed, let’s test them to see if they need further persuasion.

You’ll need a piece of flat, knot-free softwood like pine with one straight/square edge, perhaps 150mm (6″) wide and 19mm (3/4″) thick. Use your marking knife and hardened square to mark a line on the wide face perpendicular to the straight edge. Clamp this board to your supporting bench or sawhorse with the line you just made hanging off the side.

With the saw’s edge angled about 30˚from the horizontal plane (surface of the board), begin a cut from the far end of the line. use a light touch and let the saw cut where it wants to cut. Does the saw cut a straight line, or does it tend to wander to the left or right?

You may not be able to tell from this initial test, but pay attention when using the saw to see if it tends to wander from the line. If it does, the teeth on the side of the blade it tends to drift towards may have too much set, in which case use the same stone and lube to joint the teeth on the offending side. Be very gentle because there’s a risk of making it worse.

Again, be aware that side jointing the teeth means you will have to joint the top of the teeth more than usual next time you sharpen them reducing their length and the overall lifespan of the blade that much more. This is not a big loss for kaeba saws, but will reduce their lifespan.

Improvement No. 2: Tuning The Back

Straightening a kinked and/or twisty saw can be a little like wrestling the carp in the wood block print above. I don’t know the story depicted here, but I’m pretty sure it’s a scene in a kabuki play. The guy in middle with the sword is an actor named Onoe Tamizo playing a carpenter named Rokusa. The guy on the right with the ugly scowl is played by Banto Hikosaburo (no sword visible). The lady (?) on the right with the short sword is played by Onoe Eizaburo. These are all male names because men play the female roles in kabuki plays, and acting troupes then were often related as they are now.

Dozuki saws have steel backs used to stabilize the thin blade and protect it from buckling. In the traditional saw this is a folded strip of steel that clamps over and tightly grips the back of the blade, much like Western backsaws. In the case of kaeba dozuki saws, however, the back cannot tightly grip the blade too tightly or it will be impossible to replace the blade, reducing the money, money, money, money, mo-ney the manufacturer needs Gentle Reader to contribute towards his purchase of that new Italian sportscar and the Greek vacation he promised two of his girlfriends (at the same time?).

The problem is that this necessary “tolerance” (aka “slop”) often allows the blade to wander more than is necessary. But what to do? I propose three useful techniques below for Gentle Reader’s kind consideration.

Deburring the Slot

The first item we need to check for is burrs inside the slot in the back. This is not a frequent problem, but it does occur.

Begin by removing the blade from handle/back, reversing it, inserting the nose or tail of the blade in the slot, and without cutting your hand, running it back and forth in the slot. This should give you a good idea if there any big burrs or restrictions in the slot. If you find any, mark the location on the back with a marking pen.

Next, and while it may imperil your extravagant income and glamorous lifestyle as an international hand model, run your fingernail inside the slot checking for burrs that might tend to tweak the blade this way and that.

If you detect any burrs, a skinny deburring tool might get rid of them. Be careful that bits of metal don’t fall inside the slot.

Or, you can fold a piece of wet/dry sandpaper (220 grit?) in half and run it back and forth in the slot where the burrs are hiding removing/smoothing them. Some of that spray lube might help. When doing this, once again be careful to prevent large pieces of metal from falling inside the slot. When done, thoroughly flush out any swarth and bits of metal with a few squirts from your can of spray lube or brake cleaner while swinging the handle like a helicopter rotor blade. I guarantee The Mistress of the Blue Horizons will neither understand the importance of this manly ritual nor appreciate the artistic spots it may leave on her walls and ceilings, so I suggest you perform it outside, with style and grace of course.

Straighten the Back

With the slot safely deburred, let’s next consider the back’s straightness. Obviously, if a saw’s back isn’t straight, the blade won’t be either, and the cut it makes will tend to wander. So you need to check the back, and if you determine it’s out of wack, correct it.

The back, being made of folded sheet metal, is not a precision-milled component, so please don’t expect perfection, and firmly quash any OCD persnicketiness.

With the blade installed, use a precision straightedge held against the sides of the back with a lightsource to check for bow and gaps. Be sure to check both sides. A steel straightedge like that of a combination square will work, but a thinnish beveled-edge straightedge like our 400mm stainless steel straightedge by Matsui Precision works best.

A feeler gauge may be helpful in evaluating any gaps.

Straightening the back is not something readily done with a hammer for a number of reasons, but we can bend it straight if we are careful. To do this, lay the saw, with blade attached (this is important), on a flat workbench top or board with the cupped surface facing up. Place a stick of wood under and perpendicular to the back at the lowest point of the cup. The thickness of this stick is key and will take some trial and error.

Place one hand pressing down on the end of the back where it joins the handle, and the other hand on the far end. Press down slowly and carefully, bending the back without taking it past the yield point where the back will permanently bend. The back should rebound when you remove pressure, returning to its original shape without permanent deflection. Repeat this until you develop a sense of the pressure required to reach, but not exceed, the “plastic limit” of the back. You may need to add to the thickness of the stick used to spring the back.

When you have a good sense of the pressure required to just reach the plastic limit, press down on the back again with a little bit of extra pressure causing the back to permanently bend just a tiny bit. No pro-wrestling moves, please. Check the back with your straightedge to determine any improvement in straightness.

The same bending action can be achieved by placing the back, with blade attached to keep the slot from closing up, in a vise with padded jaws. Don’t clamp the saw in the vise tightly, but leave a little gap, and press on the back where it joins the handle, not the handle itself. This technique works well, but since it’s a bit more difficult to feel the plastic deformation of the back, and to control the point of flexure, it requires more self control. Please keep that darned inner badger under tight control.

If the back is snaking this way and that (very unusual), you can try the same technique in various directions.

Check progress with your beveled straightedge frequently.

If this doesn’t work, and your dozuki still refuses to make high-precision cuts, bite the bullet and replace it.

Tuning the Slot

Now that the blade slot is deburred and the back is fairly true, the next step is to determine if we need to improve the gripping pressure of the back on the blade.

This is a difficult job because we need the back to apply enough pressure on the blade to hold it in place without wiggling, but too much pressure will make it difficult to remove and replace the blade without damaging it. So begin by checking the fit of the blade in its slot.

Insert the blade and, while holding it under a strong light, push it right and left paying attention to any gaps that may open between blade and back.

If you discover any significant gaps, mark the locations on the back with a marking pen. A feeler gauge may be helpful. You will need to judge if the blade wiggle caused by these gaps is enough to warrant an attempt to close the gaps.

There are two ways to close any gaps; Both are risky. The first is to use a small hammer to tap tap tap on the back. The second is to use a vise or a C clamp to close the slot. Either way, be sure the blade is in the slot when you execute.

This concludes our tome about handsaw history, advanced business management techniques, rodent cuisine and modern marriage. I hope you found it informative.

YMHOS

If you have questions or would like to learn more about our tools, please click the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

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Japanese Exchangeable-blade Handsaws Part 1 – History & Varieties

When God means to punish a man He sends him stupid friends and clever enemies.

Joe Abercrombie, Best Served Cold

Introduction

Gentle Readers are probably familiar with the modern mass-produced mass-marketed exchangeable-blade handsaws made in Japan. In this first part of a two part series we will briefly examine the history of how these saws came to be, how they are manufactured, and the market forces that made them so popular in Japan and even overseas.

In Part 2, to be published later, your most humble and obedient servant will list pros and cons and share some techniques for improving their performance.

Gentle Reader may already be aware of these saws and even own and use them at work daily, but in this article your humble servant will share details about them not available elsewhere. I pray it proves informative, or at least entertaining.

Terminology

In the Japanese language the type of consumer-grade handsaw I mentioned above with blades that can be removed and reattached to a handle mechanism are called “kaeba nokogiri” (kah/eh/bah nokogiri 替刃鋸) meaning, of course, “exchangeable-blade saw.” From this point forward I will call them “kaeba saws” for brevity. They have entirely replaced traditional forged handsaws in Japan for good and valid reasons, and indeed are popular throughout Asia as well as Western countries too.

So let’s begin this adventure by considering the history of this new version of an old tool that shook the handsaw world like a terrier does a rat.

Historical Background

In the late 1970’s the kaeba handsaw appeared in the Japanese market changing everything.

I’m not sure who first developed the concept, but there’s no doubt it was inspired by the convenient and highly-profitable bits and blades used with powertools. The first automated equipment for making these sawblades was developed by a 150 year old company located in Sanjo, Japan that shifted their traditional saw sharpening business to producing and selling CNC saw sharpening machines. Later, inspired by automated circular-saw blade production techniques, they went on to develop CNC machinery to fabricate handsaw blades in an automated production line.

Production Methods

The manufacturing process begins with materials, of course. The primary material is pre-hardened sheet steel sanded to uniform thickness in rolling mills, and delivered to the blade manufacturer in large, heavy rolls. This product means the blade manufacturer doesn’t have to sort, forge, heat-treat, stress-relieve, or taper-grind the steel. In fact, he couldn’t even if he wanted to.

As this roll of sheet steel is unspooled into the production line, CNC machines cut and deburr the blade blanks, punch the teeth, and shape and sharpen them with special abrasives, after which set is applied by machine. And unlike traditional hand-forged fixed-blade saws, the plates are not forged, taper-ground or heat treated by the saw manufacturer at all. This is an important distinction to those who know saws from shinola.

Some but by no means all such blades are tensioned between two steel rollers in imitation of the techniques used during the manufacture of circular saw blades.

Most kaeba manufacturers induction-harden just the tips of the teeth of some blades for extra durability as the blades are fed between, and instantaneously heated red hot by, electrically-charged copper blocks, then immediately quenched in coolant spray after exiting the induction blocks leaving them a darker oxidized color. These blades cannot be sharpened by hand as the teeth are harder than files.

Handles

Kaeba saw’s handles are sometimes made of wood, sometimes of plastic, and sometimes of rubber over plastic. The blade is secured to the handle by metal mechanical widgets and sometimes screws integral to the handle. The blades can be quickly and easily changed encouraging consumers to do so frequently, but each manufacturer’s blades will fit only their proprietary handle locking the consumer into buying proprietary replacement blades, much like printers and ink/toner cartridges, because as the O’Jays sang on Soul Train, it’s the blade that makes the money, money, money, money, mo-ney, but it’s the handle that drives market share.

And with labor costs to produce such a handsaw a single digit percentage of what’s required for a traditional handsaw, the few manufacturers of kaeba saws find it difficult betimes to wade through the mountains of mad stacks laying about.

With the production technology perfected, compatible materials available, and CNC machinery in the hands of a few manufacturers, it was only a hop skip and a jump to widespread sales of kaeba handsaws, and if I may paraphrase my old carpenter foreman Uglúk, it looks like rats are back on the menu, boys.

Some prefer their rodent roasted on rye with horseradish sauce, but I prefer mine sauteed with a drop o’ Tabasco Sauce, or as Bert suggested, maybe even a floater for delicately piquant flavor! What about you?

The Societal Impacts of Kaeba Handsaws 替刃鋸の波及

I mentioned above that this new type of saw changed everything. Of course, that’s a bit of an exaggeration because babies still love boobies and politicians graft, but indeed some things changed drastically in Japan.

The first big change the kaeba handsaw wrought was putting nearly all the traditional sawsmiths in Japan out of work in a matter of a few decades. Indeed, the number of sawsmiths still forging traditional saws full-time nowadays can be numbered on the fingers of one hand after a manicure using a tablesaw.

The second domino was the near destruction of the saw handle industry. As the demand for exchangeable-blade handsaws ramped up, the production of traditional handsaws, along with the need for traditional handles, crashed.

You see, exchangeable-blade saws have patented brand-specific wooden handles with integral metal mounting plates/screws/clips to which the specific blade-maker’s replacement blade is attached. The maker of each brand of exchangeable-blade handsaw subcontracts the production of their handle to specific suppliers, and since the producers of handsaws are now few, so are the handle suppliers. Sadly, your humble servant is aware of only one, and occasionally two producers of traditional handles still operating. I believe they still have all their fingers but I’m concerned one gentleman’s liver has seen better days.

Just when it looked like things couldn’t get worse, the third domino fell-over and crushed the saw sharpening trade. While many kaeba saws can be resharpened, some cannot be economically resharpened at all because their teeth are induction-heat-treated to be harder than sawfiles. In fact, while it’s usually a little cheaper to have even a kaeba sawblade professionally sharpened rather than purchasing a replacement, buying a new sawblade and tossing the old one is quicker, more convenient and obviates the need to carry spare saws to a jobsite because thin, lightweight replacement sawblades will suffice. In any case the jobs of saw sharpeners (metateshi meh/tah/teh/she 目立て師), like those of sawsmiths, handlemakers, wheelwrights, and honest climate scientists have been practically eliminated.

The one overarching societal lesson one can take away from this is that technological advances always have and always will engender painful changes in every industry in the world, and the case of the Japanese handsaw industry only confirms that one can either ride the train of technology sipping tea and eating pringles in comfort as it rolls along, or grease the tracks as it runs one over. Just ask the once mighty Eastman Kodak company of camera and film fame if ‘taint so.

A similar progression occurred within the saw manufacturing industry in the West, but instead of the changes stemming from product innovation, the causes were quality adulteration, active neglect of customers needs, and abandonment of unparalled tradition. Welcome to the Harvard School of Business Management’s model of “profit through disruption” in action. I hear they’re looking for a new university president.

An American Handsaw Maker

To this point we’ve taken a shallow look at Japanese handsaws, especially the impact of the kaeba variety on Japanese markets, but highly intelligent Gentle Readers (could there possibly be any other kind? absolutely not!) may wonder how in heck these strange Japanese products managed to make such profound inroads into Western markets, so a few points about a well-known American saw manufacturer may prove instructive.

Gentle Reader may recall that the famous American handsaw manufacturer Henry Disston (1819–1878) was born in England the son of a designer and manufacturer of lace-making machines and immigrated to the USA in 1833 along with his father and sister. His father died three days after stepping off the boat. Tough luck.

Being a determined and diligent young man, Henry apprenticed himself to a saw company in Philadelphia, Pennsylvania. In 1840 he went independent, and after some lean years building a reputation for quality, he founded the Keystone Saw Works there in 1850. After the American civil war his son Hamilton joined the business and Henry changed the company’s name to Disston & Son, and later to Disston & Sons. At its peak Disston & Sons was the largest and most productive saw manufacturer in the world with 8,000 direct employees working on 300 acres.

At the time he established the Keystone Saw Works, nearly all tool steel used in North America was imported from Great Britain. This was a serious impediment to growth so Henry established the first crucible steel mill of consequence in the Americas to supply steel for his products and to support the war effort, and although other more famous, ruthless individuals falsely took credit for developing steel production in America, they were originally only Henry’s customers. For the next 25 years, the Disstons were among the largest producers of quality tool steel in the world outside England.

Interestingly, American consumers at the time were absolutely convinced that only Birmingham, England could make quality tool steel, so while other American sawmakers imported their steel from England, D&S used their own steel, avoiding the high import tariffs of the time. But to avoid the stigma of being seen as a “colonial product,” for many decades the acid-etched engraving on Disston & Sons’ sawblades included variations of the words “London Spring Steel” intimating that more prestigious British steel was used. Interestingly modern chemical analysis suggests that D&S’s tool steel was at least as high-quality as that imported from Britain at the time.

The first handsaw I owned as a young man was an antique and terribly rusty D&S D-8 thumbhole rip saw missing a handle (but with partial screws) I found languishing in a joint compound bucket in the back of a Las Vegas pawnshop. My penny-pinching carpenter father said it could be restored to be a better saw than I could buy new, and at $3 and a lot of elbow grease, the price was right and so was he. After derusting the blade, making a handle from a piece of scrap walnut, and reworking the teeth several times until I got the nack, that antique D-8 became an excellent handsaw, far superior to the new Disston saws still available at the time. My son owns it now.

A classic 28″ Disston D-8 swayback rip saw with a 2 hand thumbhole stock. Not my rescue saw but close.

The first point I want to make in this section is that by the time I was old enough to want to own a handsaw, the circular saw ruled the construction industry in the West (but not yet in Japan) and most younger carpenters neither owned a decent handsaw nor could care less. As a result of these market changes, the production and sale of handsaws became less profitable, the quality of those available became shamefully degraded, and instead of increasing production efficiency, and/or innovating like Japanese saw companies did, D&S did a double doodoo on quality, then lay down to be eaten by vultures. Other than a few tiny, recently-established boutique backsaw makers, the once-mighty American handsaw industry is now as dead as decency.

My second point is that this shameful degradation and subsequent abandonment of a once huge and profitable American industry fomented despair among Western woodworkers who needed quality handsaws but couldn’t procure them new anymore forcing many, like your humble servant, to haunt flea markets, pawnshops, and later Ebay for old handsaws (including Disston & Sons products) and to even purchase tools imported from Japan back when Japan’s reputation for quality was not as shiny as it is now. These forsaken and “disrupted” woodworkers, hungry for better tools, were the primary reason medium-quality but very sharp Japanese crosscut handsaws first became so popular in the USA. And when Japanese kaeba saws became available later, overseas markets snapped them up like the proverbial duck on a June bug.

FYI, the Disstonian Institute website has some interesting information about Disston & Sons those interested in history may enjoy.

As an aside, I noticed that Disston, now the Chinese holesaw maker, is offering a newer version of the D-8 26″ swayback rip/crosscut handsaw exclusively on Amazon. It looks shiny! The country of manufacture and local content is not listed anywhere, but probably not the USA and definitely not Philly. The video on their website almost made your unworthy servant spew chunky chunks. Consider yourself warned.

Let us next shift our attention back to the kaeba saw and consider the first and most popular such handsaw, as well as some other popular varieties.

Dozuki Kaeba Handsaw

The dozuki handsaw was the first Japanese kaeba saw to become popular overseas, perhaps initially attracting attention because it vaguely resembles the petite “gents” back saws once popular with amateurs. The dozuki is a thin crosscut backsaw (a single-edged handsaw with a steel or brass stiffener attached to its back) that cuts on the pull stroke.

The name is pronounced dough/zoo/key and is comprised of two Chinese characters: “胴” pronounced “dough” meaning “trunk” as in the trunk of a tree or the human torso, and 付き pronounced “zookey,” a verb meaning “to attach or make.” To the best of your humble servant’s understanding most Western woodworkers are unaware of the name’s meaning or the saw’s specialized purpose but nonetheless they use them for everything but spreading jam on toast (marmalade gums up the teeth terribly). The name refers to the job of cross-cutting the shoulders of tenons, but not the cheeks, which is a job for the specialized “ hozohiki” rip saw.

A 210mm dozuki crosscut saw with fine teeth for precision work. The manufacturer calls it a “kumiko” saw after the narrow slats found in traditional decorative joinery such as shoji and ranma. The teeth are not induction hardened. The fit between back and blade is pretty darn good and it makes excellent cuts, but the teeth have too much set for the highest-quality work.

In the case of joinery, furniture, cabinetry, and fine architectural woodwork, well-made mortise and tenon joints are essential to the appearance and even the strength of the finished product. And since the shoulder is the only visible part of most mortise and tenon joints, shoulder appearance is important.

Cutting tenon shoulders in a craftsman-like manner in the Japanese tradition demands not only a good eye, a good saw, and a skilled hand but speed, because the craftsman is expected to saw deftly, precisely and cleanly to the layout line the first time every time, all day long. This differs from the inefficient, amateurish methodology for cutting tenons in cabinetry and joinery as taught by the Holy Masters of Woodworking in the West who lack adequate saws and/or skills and shamefully advocate cutting wide of the layout line and sneaking up on it with chisels and planes. How embarrassing.

A quality dozuki saw is extremely effective at making these cuts. To do so it must be able to make a straight, precise, smooth cut right to a final layout line every time without wandering off into the weeds and without having to use a paring chisel or shoulder plane to obtain a clean, square, straight shoulder. Accordingly, it must have a thin, true plate that won’t produce excess friction, nor buckle, oil-can, or bind as it heats up, and fine, uniform teeth with minimum practical set. It must also have a lightweight but rigid steel back that effectively keeps the blade’s plate true, protects it from buckling, and discourages it from weedy adventures.

Kaeba dozuki saws come in various lengths ranging from 150mm to 240mm. TPI varies with maker. Zetsaw by Okada Industries is my favorite kaeba brand and makes some with induction-hardened teeth that can be made extremely useful with the modifications I will share in Part 2. FYI, your humble servant does not sell Z-saws and has never received free (or even discounted) samples, nor been wined, dined laid or paid to promote them.

Interestingly, even before the development of the exchangeable-blade kaeba saw, the Japanese dozuki saw was used in the West for cutting dovetails, a job which requires occasional crosscuts but frequent rip cuts, something the hozohiki saw does much better. In any case, that Western woodworkers ended up preferring the Japanese dozuki saw for even rip cuts may give Gentle Reader an idea about the comparatively adulterated performance of readily-available Western dovetail saws from the 1970’s onward.

The kaeba concept has been expanded to include useful saws of many shapes and sizes, some of which your humble servant owns and uses, especially when there is a risk of damaging one of his professional-grade fixed-blade handsaws.

Let’s next consider some popular varieties of kaeba saws other than the dozuki and hozohiki.

Kaeba Crosscut/Rip Saws

The best selling Japanese handsaw both domestically and internationally is the standard single-edged (“kataba”) carpenter’s crosscut saw. These come in various lengths, shapes, and with various types of teeth. They are handy in the shop, and I always have one or two of these on hand when working in the field, especially when cutting EWP (engineered wood products) which I refuse to allow my hand-forged saws to even touch no matter how much they wiggle and whine. If you need to cut plywood or other EWP, these saws are a must-have IMHO. More on this subject in Part 2.

A 265mm kataba crosscut saw with hardened teeth by Zeton owned by your humble servant. The blade has seen a lot of abuse and neglect. It has a paulownia wood handle still wrapped in plastic with the pricetag still attached.
A 7sun (210mm) crosscut saw by Zeton missing a couple of its induction-hardened teeth. It has a soft paulownia wood handle that has seen better days. Hinoki would have been a better wood in this case.

But the usefulness of kaeba saws is not limited to woodworking and sandwich making only, oh no. I carry a 333mm (13″) kaeba formwork saw with a lightweight plastic pistol-grip handle when hunting because no other tool I know of is so light, so compact, and can cut so much wood so quickly.

A special-use kaeba saw I am fond of, with two of its blades shown. The handle (a Zeton product) is made of fairly lightweight but tough plastic, but its most valuable feature IMO is its short length which makes it fit nicely inside toolbags and backpacks. The 300mm blade, handle, and a wooden scabbard I made to fit, goes in the toolbag I take to jobsites. I have a plastic scabbard for the 333mm saw which I strap to my backpack when camping and hunting. Much lighter and more compact than an axe.

The Silky brand arborist’s saw blades are excellent for this purpose too if you ditch the heavy rubber handle and gaudy scabbard.

Ryouba Double-edged Kaeba Saws

This style of kaeba saw combines a rip saw and a crosscut saw in one exchangeable blade. I own one 270mm kaeba ryouba saw with induction-hardened teeth I like well enough, but I still prefer fixed-blade ryouba saws. I daresay most people can’t tell the difference.

A 270mm ryouba double-edged saw with hardened teeth by Fujiwara intended for interior installation work. The blade retention bar can be seen projecting from the center line of the handle. I’m unsure if this saw is still being produced
The same 270mm ryouba saw disassembled showing handle, blade, and wire retention clip. The two bent tabs at the end of the sprung retention bar fit into the two slots in the blade when assembled.
The same 270mm ryouba kaeba saw showing the wire retention clip used to secure the two tabs that lock the blade in-place. Notice the blue-black discoloration of the sawteeth tips typical of induction-hardening.

Saws retailers here in Tokyo tell me that sales of kaeba ryouba saws have dropped off dramatically the last few years probably due to increased prefabrication and LGS metal studs replacing wood and LVL (laminated veneer lumber) framing for interiors such that rip cuts in wood in the field are seldom necessary. I believe this increase in the use of pre-manufactured components is in part due to three inter-related factors: (1) Rising construction costs; and (2) High demand in the construction industry; and (3) An aging workforce resulting in a decrease in available manpower in the construction industry making it difficult to meet customer demand. I fear the current attitude of Japanese women about bearing and raising children will prove disastrous for the nation soon as you can say “Bob’s not your uncle.”

Teflon Coated Blades

Zetsaw sells some of its blades with a PTFE teflon coating which I have found to be very effective in reducing friction and preventing sap from accumulating when cutting some softwoods. Makes a great egg turner too.

An 8sun (235mm) rip saw with hardened teeth and teflon coating by Zeton. This is an exceptionally useful saw.

The Adventure Continues

In the next installment in this operatic series about the funky love of money, fine dining and handsaws we will examine the advantages and disadvantages of kaeba saws compared to traditional fixed-blade saws, and explain simple techniques Gentle Reader can employ to supercharge your kaeba saws.

But in the meantime, since the IMF, EU and UN are on the verge of outlawing backyard vegetable gardens at the same time they are taking by force and sacrificing the land of European farmers on the alter of the religion of “Climate Change,” (how did that work out for Sri Lanka?) all while increasing pressure on others (regular people, but not the bureaucrats/elite) to substitute bugs for meat (I kid thee not), I would appreciate Gentle Reader sharing any tasty recipes you may have for crispy, crunchy low-fat rodent dishes in the comments below. I need to broaden my culinary repertoire in preparation for more societal “disruption,” you see.

YMHOS

I ain’t gonna eat no bugs!

If you have questions or would like to learn more about our tools, please click the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

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Permanence

A Huon Pine, native only to the Island of Tasmania

Serit arbores quae alteri seculo prosint – “He that plants trees labours for future generations.”

Caecilius Statius, quoted by Cicero. Motto of John Quincy Adams and his family, among others

This is a guest post by Dr. Antone Martinho-Truswell regarding a highly unusual tree, his adventures working its wood, and his thoughts about permanence. Enjoy.

What Does It Mean to Build Permanence?

Woodworkers – and especially we odder, curmudgeonly, hand tool woodworkers – have a vexed relationship with permanence. 

On the one hand, spend any time reading, listening, or talking to a woodworker of any integrity (not least our distinguished host, Mr. Covington), and you will inevitably hear about building things that last, creating furniture or structures that will outlive the creator. Or else you might hear lamentation of the impermanent, throw-away culture represented by particle board, OSB, melamine, wire nails, and so forth and so on. Stan writes regularly here about building for future generations, about tool chests that preserve and workshop stools that endure. When we chop a mortice or fit a dovetail, the idea is that the end product is permanent – the strength and durability of the outcome justifying the labour-intensive process of creating it

And yet: wood. We are not stonemasons. We are not goldsmiths. We work with a biological material, one subject to biological processes such as mold, rot, borers, gnawing things, weather, sunlight, fire and friction which eat and wear away at wood until it’s gone. Japan’s venerable old wooden structures, record holders across all human construction efforts, pale in age compared to those made of stone. Wood perishes as do all living things (at least since Valinor was sundered from the sphere of the Earth).

This is the story of a permanent wood. A wood as magnificent as it is rare, a wood that is itself a lesson in permanence, and my attempts to make beautiful things for now and the future.

Old and Young Places

I like to think about old things. I was born and grew up in Southern California, where almost everything is new, even the old things. I remember as a child a small water tower near my elementary school, proudly fronted by a sign announcing that it was the oldest building in the area – an august 25 years old. The tower is older now and so am I, but there were old trees around even then. Up north, there are sequoias and redwoods, and of course, the oldest of all, bristlecone pines. I was young then, and didn’t think too much about wood or lumber, but I knew the trees were old. 

As a young man, I moved to England for graduate school, and the world was much older. There was a sense of permanence, in the material things at least: old buildings and old furniture and old books and old wood. Oaken chapel pews and blanket chests and linenfold panelling – the sorts of adornments that, in the USA, are the enviable preserve of grand old institutions in grand old East coast cities, but in the UK, found in all manner of great and humble places. But the trees weren’t so old. England’s ‘green and pleasant land’ is green with farms and fens, but not so much old forest anymore. Like much of Europe, over aeons humans have harvested so much timber that little old-growth forest remains, only secondary growth, coppices and managed woodland. The trees in England are fairly young because the culture is relatively old. I was not yet a woodworker, and I did’nt think much on trees and timber at the time, but I knew the culture was old.

As a married man, I moved to Australia, and here I remain. The prevailing culture – that of the settlers rather than the indigenous people of Australia – is young, and so are the trees. Mostly.

Australia’s frequent natural fires mean that most of the trees that grow here are adapted to grow fast and big, but not long. Generations of forest turn over quickly – in ecological terms that is – with bushfires killing off adult trees and causing their scattered seeds to germinate and grow a generation of newer, younger trees. What’s more, as in America, the brash, youthful settler culture did not have a good track record as stewards of the natural gifts of the island continent, and the few old hardwood forests that once existed have been over-exploited. 

Perhaps with age comes wisdom, but now I am both a father and a woodworker, and I ponder permanence, and wood, a great deal, and what all this youthful forest means for woodworking here in the sunburnt country. 

Hard, Stringy Wood

If you know anything about Australian woods, you know they have a well-deserved reputation for being really, really hard.

The vast majority of our forests and the trees that grow in them are the various and many species of eucalyptus and its near relatives, with two qualities that make them a mixed blessing to woodworkers.

First, they are fast growing, so as to quickly repopulate the land after fire, and second, they are extremely hard – the softest commercially available eucalyptus wood is called “Victorian Ash” (or “Tasmanian Oak” – same wood, different source) in the timber trade with a hardness similar to white oak or rock maple. The hardness of other varieties can easily range up into ipe and ebony territory.

Rainbow Eucalyptus

The result is an abundance of eucalyptus wood great for things like flooring and fenceposts, but fast growth makes it especially stringy, which together with phenomenal hardness makes it difficult to work with handtools. That same Victorian ash, the most common of all hardwoods in commercial use here, is among the best behaved, and a straight grained piece can take a nice glassy finish from a hand-plane, but we have nothing commonly available with the smooth texture of a maple or beech. Victorian ash works like oak at best. The other good furniture eucalypt is Jarrah, which is a lovely orange-brown colour and less splintery than most, but it’s expensive and a good bit harder than maple, so still a challenge. Moreover, it comes from Western Australia, which, along with Victoria, banned all native forestry at the start of 2024, so it is likely to recede to only niche use in the future. 

There are many other beautiful, softer, easier working, and often fragrant Australian hardwoods, but for one reason or another all of them are scarce and hard to track down.

There are few species under plantation production here, and the fast-growing eucalypts crowd out most other species in our forests, so the best cabinetry timbers, like acacias and mahogany relatives, are rare. If you find these timbers for sale, it’s usually from a small-time operation that harvested a fallen tree – so you have to wait around for luck to smile on you. I try to snap up Australian Rosewood priced reasonably. The vast tracts of cabinet timber we once had – the famed Australian Red Cedar, which is actually a mahogany cousin, for example – were all irresponsibly exploited down to commercial extinction decades ago. A permanent culture of wood use requires a forestry industry with an eye toward permanence, which we didn’t have for a long time, and many argue we still don’t – hence the aforementioned bans and the limited selection of commercial wood. 

A few government agencies and private companies are trying to improve sustainable forestry in Australia focusing on Australian blackwood (Acacia melanoxylon). This species should not be confused with the African blackwood of oboe, clarinet and bagpipe fame. Australian blackwood is a dead ringer for Hawaiian koa, and is its closest living relative. It has a rich, deep, brown colour with the same gleaming chatoyancy of koa, but its name comes not from the colour of the seasoned wood, but rather the black color the sap turns sawyers’ hands.

It’s a breathtaking timber deserving of widespread admiration, and one of the few beautiful cabinet timbers down here that weren’t over-exploited to near extinction in the last century. The blackwood timber industry is apparently a bit wiser than their forebears, and so harvests less and charges more to promote sustainability. It’s the nicest timber that can be bought here straightforwardly, and is priced accordingly.

The Ships that Took Our Trees

Clipper Ship, City of Adelaide, 1000 tons

Of particular interest to users of Japanese tools and Japanese woodworking methods and mindsets are softwoods, and this is where Australia is confusing. There are no true pines native to any part of the Southern Hemisphere – but settlers insisted on naming all the fascinating and unusual softwoods down here “pines” – and then importing a northern hemisphere species for most of our plantation wood.

Norfolk Island Pine

Norfolk Island Pine

When Britain established the first penal colony at Sydney in 1787, the site was chosen partly because it was thought to offer a good strategic back-up to the British claims on Norfolk Island – a speck 900 miles out into the Pacific. The trees covering this island – Norfolk Island pines – were thought to be particularly valuable to the Royal Navy, as they tended to produce ramrod-straight single trunks, almost as if replacement masts had been conjured up from the Earth. However, the timber proved too flexible for masts, and the idea was abandoned, though the Norfolk pines got their second act as a popular ornamental plant (including a few all the way back in my home town in California).

Hoop Pine

Much more useful is hoop pine, a near cousin of the norfolk pine that grows on the Australian mainland, and is our only plantation-grown native conifer. I’ve made shoji from hoop pine; it has nice straight grain producing a good shine when hand-planed. The only other commercially available native softwood is Australian white cypress which has a beautiful smell and is famously insect resistant, but unlike most softwoods it’s harder than American oaks. It also doesn’t grow very big, so is mostly used for knotty, sapwood-sapwood edged fence posts, or equally knotty floorboards and decking. I understand that it is not a sustainably managed species, and conservationists often recommend against its use. 

Monterey Pine

The Australian construction industry relies on plantation grown monterey pine (also called radiata or pinus radiata) for all of its general purpose lumber. This is an import from California, now very rare in its natural habitat but grown all over the Southern Hemisphere to compensate for a dearth of native pine species. It is a particular pet-hate of Australian woodworkers, in online forums and general conversation, who lament its often crumbly texture and poor strength. I don’t hate it though – it can take a lovely plane finish and the wide grain does make for beautiful patterns on clear, flat sawn boards.

Huon Pine

Like all Australian trees, huon pine is misnamed. It isn’t a pine at all but rather the only member of its genus – more akin to a cypress than anything else, yet still not a cypress, a thing of its own. 

Fans of Tolkien’s works may lament that its name is Huon and not Huorn, but no tree was ever more deserving of association with Tolkien’s tree-herding Ents, that ancient race of sentient defenders of the forest.

Huon pines grow only in Tasmania, and only in the wet and mountainous western regions protected from fires. Provided they have that protection, they may achieve something most Australian trees do not – great age. Huon pines grow incredibly slowly, barely thickening as century after century wash over them, living at least 2000-3000 years, with some thought to be even older. This is best evidenced in the astonishing tightness of their annual growth rings. It is not uncommon to see specimens with annual growth less than half a millimetre – or to put it another way, the trees gain less than two inches of trunk radius per century. While immensely slow, these trees can still grow immensely large when given that precious critical thing – time. They are probably the longest-lived trees in the Southern hemisphere, and certainly in Australia.

There are lots of small huon pines growing now, though few big ones. They should be huge, but they are not, because the great ones were all mostly cut down to build boats – a vast fleet of huon pine watercraft were constructed in Tasmania, using up most of the big trees. The promise of the perfect tree for shipbuilding that had fallen flat on Norfolk Island paid off big time in Tasmania with the huon pine. The reason for the single-minded use of these ancient trees for shipbuilding will become obvious, but as a result of this hasty zeal, they are now the single most protected species of tree in Australia, both to allow the forest, with Ent-like patience, to recover, and to preserve the few very old and very large specimens that remain. 

Beyond the Grey Rain-curtain

These trees are old, though their lives are but the beginning, and death, as Gandalf once taught young Peregrin Took before a fateful battle, is just another path beyond which the journey does not end. This is, cynically, true of all wood that gets put to human purpose, but it is true in a special way for huon pines because of a unique chemical in their wood. Not unlike other fragrant cypress-like softwoods – including Japanese hinoki – huon pines contain great amounts of oil, in this case, an oil called methyl eugenol that protects them from insects and other wood-hungry nasties. Methyl eugenol is, as it happens, the ticket to eternity for wood. 

For whatever reason, methyl eugenol, in the very high concentrations in which it is found in huon pine, is astonishingly successful at preserving timber. Huon pine timber is highly prized for shipbuilding because it’s easy to bend and work, completely impervious to insects and fungus, and readily survives the rigors of the aquatic environment. All that ever seems to happen to huon pine is that the surface turns grey in the sun – much like teak. And then it simply endures. 

And I mean it endures. The 3,000-year age of living huon pines is one thing, but researchers have found fallen huon pine logs on the floor of the forest that have lain there, unmolested by decay, for as much as 38,000 years! Not petrified, not fossilized, just oily wood under a weathered surface, simply enduring. 

These characteristics are also why we still have a bit of precious huon pine timber available nowadays, reclaimed from time to time from old boats and old furniture, as durable and enduring as ever. Moreover, the foresight that was missing when the trees were mostly cut down a century ago was not blind when hydroelectric dams came to Tasmania. In the 1970s, with two valleys set to be flooded, the Tasmanian government allowed loggers to go into the valleys and cut down the pines – but not to take them. The loggers, working in tall boots even as the dam waters were rising, would leave the logs where they fell, to float up to the surface of the new lake as the waters rose. 

That was 50 years ago – the logs are still there, floating on the lake. The outer layer turns grey to about 1-2mm in, and then, inside, the creamy golden wood, as perfect as the day it was felled, endures. The decades afloat harms it not at all, and every year a tiny portion is licensed to be taken for restoration and preservation jobs.

This is all the unreclaimed huon pine that there is or ever will be for woodworkers to use, and they estimate they have about 50 years’ worth left at current extraction rates. But with the wood so impervious and eternal, what is already in cabinets and drawers and tables and ships will continue to circulate and be reused. It is a wood with true permanence.

An Unexpected Responsibility

At this point I will enter the story to share the most harrowing and rewarding of my experiences as a woodworker.

By chance, I had the opportunity to acquire three large slabs of huon pine, cut and dried in ages past but never used. Compared to the tiny crafting boards and turning blanks that are generally available (at great price), this was a bit of a windfall. I could have, with all cynicism, listed each one for sale for several hundred dollars, pocketed the profits, and went on to buy more quotidian woods. I did not do this for two reasons.

First, and perhaps most pointedly, with visions of epoxy pours and hairpin legs plaguing my dreams, I was overcome with a sense of responsibility to “protect” this precious wood – whatever that means. I wish to acknowledge, in self-reflection and humility, that I am an amateur woodworker. A reasonably experienced and meticulous one – but an amateur nonetheless, albeit one who works with hand tools and has the hand tool mindset. My work is fine but not perfect. But I suppose I like to think that the tool marks I leave here and there, occasional tear-out, and other mistakes that remain have a certain honesty and worthiness to them, becoming of a slab of great age. Vanity of vanities, all is vanity…

More than that though, I saw in these slabs of huon pine, and in the legends of these trees, an opportunity for permanence. Here were three great hulking slabs of a tree older than the nation-state it was felled in (I counted 800 growth rings on one of the slabs – and it wasn’t even a centre slab), thick and strong, and made of the closest wood comes to being an imperishable material. Here was the opportunity, if it was ever going to exist, for a piece of furniture that might outlive the memory of my name. 

It had to be a table. Only a table could use to best effect the wide expanses of precious wood – laying them out on full display for all who saw them to admire. No matter how perfectly I might make a cabinet or chest, it would not do justice to the material. And, as history, archaeology, and literature show, only a table is so intimately connected to life and family and holiness by its proximity to hungry mouths, little hands, and eager minds as they first do their colouring and then their maths homework, and then their college applications. Only a table is ever so truly loved by generations as to be worthy of wood older than all those generations combined. I simply couldn’t bear cutting the beautiful slabs into small pieces. So for months I fretted; and worried; and stressed about the crushing responsibility of making the first cuts. 

The Weight of History

I am an apartment woodworker. My family home is a house in the mountains west of Sydney, but I work as Dean of a university college and we live most of the time in the Dean’s residence, an apartment on campus. I am blessed with a very patient and indulgent wife and an apartment that happens to have a sort of wide corridor I use as a tiny woodshop. Space is still limited, though, and I try not to stockpile wood (in the interest of stockpiling tools – ahem). So, three slabs, two metres long and the best part of a metre wide, mocked me each time I had to shuffle past them. And still, I fretted. 

I eventually decided upon a refectory table so that no matter how many chairs are crammed around it, none clash with the legs. And with a strong stretcher tusk-tenoned into each leg to allow it to knock down, so that I could make it big but still fit it through doorways. Most importantly, I needed to keep the two 800mm wide boards that made the tabletop flat – so sliding dovetails across the bottom to counteract any cupping. And those sliding dovetails would be a perfect place to pin the top to the legs, with removable dowels, again so it could be knocked down to move. Drawbored mortise and tenon joints to hold the I-shaped legs together without glue (since all that wonderful oil makes gluing troublesome anyway). A kanna-shiage (handplane finished) top for beauty and touch, with just a light coat of oil and hard wax, so that the wood itself can be appreciated. A magnificent vision. Complex and well-chosen joinery. Perfection worthy of the tree. Entirely beyond my experience or skills…

I had to start by getting to know the wood. Before any cutting or marking or anything, I realized I could not confront the massive task I had set myself without first knowing what it was to get huon pine under saw and plane, to see, feel it, and smell it.

.

 

I hoisted one of the slabs onto my sawhorses, and with a few strokes of the little aogami roughing plane on the left, and a few more of the shirogami finishing plane on the right, I had my first look at the slab, and my first curls of huon pine shavings. (No, Stan, I don’t London finish my plane bodies. They are dirty, it’s patina.)

The smell – oh the smell. The smell of huon pine is unlike anything I have ever experienced. It is sweet and rich and almost creamy, but without even a hint of sugariness or caramel, nor any of the medicinal notes of cedars or cypress. I suppose the aroma is a little like gardenia flowers, but different. And it’s persistent. I saved bags of little offcuts that are no less fragrant now than a year ago. 

The scent was such that I almost did not notice the figure at first. From some angles, nothing more than a very tightly grained, golden softwood, with rippling grain caused by the irregular growth of the tree’s surface over the centuries is visible. But when the light strikes the surface of the top at the right angle, a shimmering sea of lamellar rays cutting across the grain pop out, almost obscuring the grain with its gleam. Beautiful but subtle – much like the scent. This image and this aroma is now linked with permanence in my senses.

With the feel, smell and appearance of the wood now embedded in my mind I began to feel more confident about beginning my table project. One serious concern remained, however, namely: tear-out.

Layout That Fills the Workshop

I started in with trepidation, hoisting the two closest matched slabs onto my horses and getting to work. In my little shop, I have no room for a great big assembly table, so the slab was my workbench, and took up the whole shop. Here you can see my cramped little shop, replete with little atedai against the wall, assorted tat taped and hung on the walls (including my Palm Sunday palm, awaiting the coming Ash Wednesday), my tool chest brusquely stolen from Stan’s design, and a lovely old tansu filled with bric-a-brac.

Layout was painstaking, although not because the joinery was especially complex. Before shaping, the two “I” shaped legs were six simple boards and the stretcher would resemble nothing so much as a 2×4. The only complexity to the initial layout arose from the graceful radius I had planned for the long edges of the two top slabs. I could have cut them with straight edges and cut the curved edges later but that problem would have been unnecessarily wasteful. 

One simply cannot waste this wood. If you have any respect or regard for the trees that support our craft, it repulses the conscience to even put plane shavings into shop bins. Moreover, I absolutely refused to cut these slabs in anything but the most efficient, offcut-preserving way. As a result, layout took days (or, rather, nights. Amateur, remember?).

The two surfaces of the slabs I used for the top each had unique flaws and virtues. In the end, curving the tabletop’s edges to accommodate the natural edges and features of the slabs proved effective in maximizing the tabletop’s size while minimizing waste of this rare and valuable wood. For example, in the photo above you can see where the near right corner of the slab narrows towards the end, an inconsistency my layout had to accommodate. This layout was also necessary because two of the slabs were contiguous in the bole and one was not, such that the two contiguous, matched slabs had to be used for the top even though one was somewhat larger than the other.

Dealing with the constraints that imposed this layout taught me important lessons in collaborating and compromising with the wood. In line with Japanese tradition, I knew I wanted the “outside” surface of the board to be oriented upwards in the table, and so my layout prioritized that side. As a result, both slabs ended up with prominent natural flaws on the underside – like greyed areas, bark incursions, and even one gash that looked as though the tree had been struck with a red hot poker.

There is a school of thought in modern, machine assisted, YouTube recorded woodworking that cannot tolerate such defects, no matter how small or natural, in any piece of furniture, demanding they be either removed entirely or filled with colored epoxy. The first approach I reject because wood is natural and I believe it should feel natural. I enjoy the fragrance of the wood, and the feel of running my hand along the underside of the table, sensing the evidence of the tree’s story, together with the tool marks I intentionally left. The latter approach I reject because epoxy is plastic, and I work with wood. The table bears the scars it earned in life, but only reveals them to those with enough appreciation and humility to get down on their hands and knees to gaze upon them. 

Putting Blade to Wood   

I do not now, and suspect I never will, own a table saw. Someday I might own a bandsaw, but I’m not convinced. In any case, I won’t have any of these things in the house whilst my daughters are young, as much to spare my family’s lungs from dust as to avoid injuries, however unlikely. 

So that meant I had to figure out a way to accurately break down these slabs along my layout lines with hand saws, in a room that barely contained the slabs. 

I couldn’t do it on the sawhorses – that would require me to stand on the slabs to make the long rip cuts, which seemed risky to their integrity without a supporting table underneath, especially when sawing the narrower pieces. And the slabs were too long and too heavy to comfortably use the Japanese low horse and foot-clamp method, which I am normally fond of for long rips.

The solution I selected was to support the slabs horizontally on one long edge using my 6-inch thick planing beam, with the other long edge supported on low horses with extra boards taped to them to make up the difference in height. This provided enough vertical clearance under the slab for a kataba saw. This arrangement had other advantages too. As I ripped from one end of the slab to the other, I could stand on the slab directly above the supporting planing beam, which was in turn resting on the floor, preventing the slab from shifting position while avoiding downward deflection of the ever-narrowing slabs.

My back did not love this hunched sawing position, but it was more comfortable than you might expect, and in two long sessions of rip-sawing, I had everything broken down to pieces: two wide top planks, each tapered on one edge, two vertical leg pieces, four feet and aprons for the I-shaped legs, and one long stretcher. As it happened (and as you can see below) the offcut from the third slab was almost a perfect extra stretcher. I still have it and will use it for something someday. It is the world’s most magnificent (and I suspect valuable) pine 2×4. The two venerable katabas, one rip and one crosscut, may be seen taking a well-deserved rest after rendering magnificent service. 

With designing, planning, layout and rough cutting done the project shifted to the shaping and joining phase requiring greater attention, so I put down the camera, and did not pick it up again until the job was done. Sadly, I don’t have photos of gorgeous shavings rippling off planes, or of the massive Anaya-nomi I used to cut the mortises for the stretcher to pass through the legs, or of the nakin-kanna rounding off edges. 

This work was more-or-less conventional furniture-making; taking the neatly rectangular pieces of wood I made in the rip-fest above and shaping them into components using good steel and keen eye. I didn’t follow a borrowed or historic pattern for any of this, but worked out my own take on the refectory style of dining table with two I-shaped legs and a single stretcher.

I made a pattern of a single asymmetric curve using a bit of sturdy brown paper shopping bag, leaving the carry handle attached to hang it on my shop wall throughout the process so it was always to hand. I used this same curved pattern throughout to define all the curves in the project, starting with the concave slope from the mortise in the feet to their toes, the tapers from centre to ends on the vertical legs, and again as the most important curve in the project – the gentle swell of the tabletop’s long edges from one end to the middle and then tapering back to the opposite end again. 

Once the base was completed, the conventional woodworking ended and the real gauntlet began – the top. 

The top was made with the two long, wide boards shown with my kataba saws in the photo above. At almost 400mm wide each, they were a challenge to handle, a bigger challenge to plane, and an even bigger challenge to keep flat. 

The work of planing the wood went alright. The swirly grain of huon pine is not terribly prone to tearout, and like all quality softwoods, is a joy to plane in the direction to which it agrees, producing shimmery, breathtaking surfaces. The trouble is that each 400mm board contained 800 years of growth rings with grain direction changing within each board many times due to storms, cool summers, and a lightning strike or two as empires rose and fell. And with such tight grain an entire century of growth, along with the changes in the tree’s environment that impacted that growth, ended up recorded within a mere five centimetres of width – narrower than the thickness of a standard 70mm kanna – and often without apparent visual clues. As a result, seemingly neat, fine ribbons of shavings pulled end to end would be followed by tiny but significant tearout here and there across the board. 

Reader, this took days – days of sharpening by very best white #1, fine mouthed, perfectly (amateur-perfect, mind you) tuned kanna. Days of shaving just exactly to this specific point, in just this direction, just so, to clear up a spot of tear out, then switching sides and going the other way, hoping and praying and watching that I didn’t overstep the boundary and have to start over – which I did, many times. And all the while, awkwardly walking around the massive slab, leaning over it to plane the far side, getting half up onto it like a billiards player, and then doing it all over again on the other slab. There is still some tear out in the surface, especially around the teardrop-shaped bark inclusion that gracefully adorns one corner of the tabletop. But it’s pretty close.

Keeping it Flat

An important aspect of the project was ensuring the wide, solid-wood tabletop remained permanently flat through changes in temperature, humidity, loading and coverings. In the case of such wide slabs, there was only one realistic solution – sliding dovetailed battens on the underside. This design detail had the advantage of providing two level, perpendicular surfaces to connect the legs to the tabletop.

Of course, a hard cross-grain connection between the battens and the tabletop using glue and screws would end in tears after just a few years, so I cut two blind sliding dovetail slots in each half of the tabletop beginning at centre joint of the toward to about 8-10cm of the edges, then cut dovetails into the battens to fit. The two planks hold the battens captive between them once installed, and the friction in the sliding dovetails locks the two slabs together without glue, dowels or hardware.

To use glue anywhere in this project seemed wrong. In any case, the oils in huon pine don’t play nicely with glue, and the joinery connections were the better plan. 

I cut the dovetails in the battens and tabletop planks using my cleverest of all Japanese planes – the male and female dovetail plane, a rare beast indeed.

With the battens installed I cut 10cm wide shallow bevels on all four lower edges of the top, tapering the top to create the illusion of a tabletop only 20mm thick from a slab about 40mm thick in the centre. This involved a lot of plane work.

I left the underside a bit more rustic, even allowing large areas of “live” bark to remain as a lagniappe to the worshipful person who surveys the underside. You might think that leaving bark on the underside meant that I contravened the usual practice of Japanese woodworkers of using the outside surface of a plank as the show surface, but no – though not Japanese, I cleave to this principle invariably, but in this case, the history of the tree involved so many twists and turns that the bark inclusion was exposed on the inner surface of the board.

For clarity, allow me to explain what may not be obvious from the photos. The two legs are connected by mortise and tenon joints to horizontal feet at their lower ends and horizontal beams at their upper ends. In turn, the trestle leg beams are connected to the two battens by four dowels, two at each batten, that pass through the beams and battens at an upwards angle. After exiting the batten, the end of each dowel presses tightly against the underside of the tabletop, slightly bending and binding it in place. 

To disassemble the table in preparation for relocating it to our home in the mountains outside Sydney, I just need to knock out these four dowels and slide the battens out of their dovetail slots, and knock out the two wedges in the ends of the tusk tenons securing the spreader beam connecting the legs. This design has worked well, and the dowels are strong enough that the table can be lifted and carried by the top alone.

The Finish

Now, a great part of me wanted to leave the wood unfinished, both to enjoy the raw kanna-shiage surface, and to ensure the magnificent smell would not be diminished. But, to provide some protection and give a bit of extra visibility to the lovely grain, I gave the wood a couple of coats of thinned pure natural tung oil, and then rubbed on and buffed out several coats of carnauba wax creating a surface hard enough to help protect the relatively soft wood from dings and scratches. Also, my wife liked the colour better oiled than unfinished, a very important consideration for all of my woodworking efforts.

And that was the job done, and here it is, in its home on the covered veranda of my house:

As you can see, the finish turned the feet, which I cut from a discontiguous slab, a darker color than the rest of the table, but it’s an effect I rather like. The clouded figure of the top shimmers beautifully in the morning light from the East, and the little imperfections quietly witness to handwork, something for me to fret over in my quietude at meals around the table. The horizontal beams at the top of each leg that mate with the battens, not visible in the photos, are identical to the feet, except of course inverted.

I do not think I am testing the permanent nature of this table by using it outdoors  – though I may move it inside for a different practical reason: it is now the largest table we have, and has already made a couple of trips inside for big family gatherings. Rather, faced with a true forever wood that can endure against the elements, it seems only right that it should experience them and demonstrate its aplomb. I am glad in the end that I did not glue the centre joint of the top surface because it allows the two slabs to move and stretch a bit on humid days without cracking or busting the seam, and while this does mean they become un-flush for a day or two, they settle back in becoming flush once again when the weather dries out. The table can breathe. 

I will inevitably make little corrections as the table and I get used to each other. I remain unsatisfied with the very rectangular shape of the stretcher, and when the time comes to break down and refinish the table I will add some curvature to the stretcher. I will also probably resurface the top perhaps once a decade, as it ages and my skill with a kanna (hopefully) improves. Part of the joy of using a wood that should outlive my bloodline to make a table of great permanence that can be disassembled and reassembled as needed is the anticipation of ongoing minor improvements, and the relationship I and future generations will have with it. 

In the end, I still do not quite deserve this wood, because no one does. It is right and just that the Tasmanian government has banned the felling of any more of these trees, and it is right and just that the remaining wood is hard to come by and cherished. I am happy for the opportunity to make something permanent with this magnificently permanent and beautiful material. 

Antone Martinho-Truswell is a professional zoologist and amateur woodworker. His work can be found on Instagram at @stjosephwoodworks, where he posts his projects, experiments, and failures, and takes the odd commission. If you enjoy his writing and want to learn more about his day job, his book, The Parrot in the Mirror, is available from booksellers online and worldwide.

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Japanese Handsaws: The Bukkiri Gagari

A 320mm (“shakuni”) bukkiri gagari handsaw with a kiri wood handle resting on your humble and obedient servant’s atedai workbench

Socialism is the philosophy of failure, the creed of ignorance, and the gospel of envy.

Winston Churchill

The goal of socialism is communism.

Vladimir Lenin

Thank you for visiting the C&S Tools Blog! This article will be a show and tell about a couple of unusual saws of a type not well know outside Japan. For that matter, they are no longer common inside Japan.

The Bukkiri Gagari Saw

The three saws pictured in this article are of a type of Japanese handsaw called a “bukkiri gagari.”

Terminology

Let’s begin with the second word in the name, “Gagari,” (gah/gah/rhi) which refers to a larger rip saw intended for rougher work. Usually forged heavier and stiffer than standard handsaws, these were once standard tools in every Japanese carpenter’s toolbox, used for ripping boards and cutting joints in timber frames. The teeth are made large to quickly eat lots of wood, but when properly sharpened, given the right set, and used correctly, they will make smooth cuts indeed.

Your humble servant has only seen the word gagari written using phonetic “hiragana” characters which are derived from Chinese characters but do not have any inherent or historic meaning, so while I can’t guess where the word came from, in exchange for a delicious chocolate chip cookie (with a glass of cold milk, please) I might be so bold as to suggest it came from the rough sound large rip saws make when ripping thinner boards.

Likewise, I’ve never seen the modifying first word, “bukkiri” (book/kee/reeh), written using other than hiragana, but even without a cookie bribe I can guess that “bukkiri” is a modification of the word “bukkiru,” which means to “chop off” something, for instance the head of a fish or an especially-corrupt politician. In this case, I believe it refers to the pointed tang having been chopped off short. So a bukkiri gagari is a larger rip saw with a shortened tang and an angled “shumoku” handle.

The Shumoku Handle

A shumoku mallet for striking small bells

The handle is especially unusual so let’s consider it next. The skewed handles in the photos in this article are called a “shumoku” (shoo/moh/kuh) 撞木 handle.

Shumoku is an interesting word. The Chinese character “Shu” 撞 means bell, while “Moku” 木means wood. In other words, a shumoku is a piece of wood for ringing bells. The image to the right is of a wooden mallet used to strike small tabletop bells during Buddhist ceremonies.

The shumoku in the video at this LINK is a tad larger, being motivated by a group of 17 jolly monks in a bell-ringing ceremony at Chion-in Temple (知恩院, Monastery of Gratitude, Jodoshu-sect) in Kyoto. Said to be the largest bronze bell in Japan, it seems to take a lot of work to make it sing!

I have no clue why this word is used for a saw handle, and those in the industry I’ve asked didn’t either. A mystery. Based on my long years of experience reading and writing in the Japanese language, it seems likely that the woodworkers that made and used this style of handle back in the mists of time gave it a name with a pronunciation similar to shumoku back in the days when few commoners could read or write, and centuries later when the came time to write the word using Chinese characters, someone decided to use the “bell wood” characters just to poke fun at the monks in their funny dresses (ツ).

Despite what those who like to portray the Japanese language as highly cultural and absolutely logical suggest, I can assure Gentle Reader it contains many instances of such strange “assignments,” just another reason why the written language is too often confusing.

Long, straight handles with oval cross-sections are more common in Japan, and certainly better known outside Japan. And the straight handle makes accurate cuts easier because one can readily sense if the blade wanders from a straight line in the cut. But, in some cases, the straight handle has three disadvantages. First, the handle’s length sometimes gets in the way when making long strokes in the tight spaces where carpenters are sometimes required to work, whereas a saw with a shumoku handle is shorter, and is easier to use from various angles, for example, when cutting a tenon or a housed dovetail from under a beam. Second, the straight handle depends on a high-friction grip by both hands to motivate powerfully, whereas the shumoku handle does not. And third, it’s more difficult to use as powerfully as the shumoku handle due to the angle of the user’s hands in-use.

Here’s are a Link to a video of a guitar luthier using a bukkiri gagari saw.

Two Examples of Bukkiri Gagari

The photo above shows two saws: the antique 320mm shakuni (1.2 shaku) bukkiri gagari as well as a longer 355mm “shakusan” (1.3 shaku) bukkiri gagari saw hand-forged and hand-sharpened for your humble servant by Nakaya Takijiro Masayuki, with teeth especially shaped for ripping hardwoods. A most excellent saw.

The shorter saw is over 150 years old, and according to the blacksmith’s hand engraving on the tang, was forged from “Tougo Reigo” steel, aka “Togo steel,” a British product made by the Andrews Steel Works and first imported into Japan by an officer who once served under Admiral Togo in the Japanese Imperial Navy and who borrowed the name of the famous military leader.

It’s a great saw, one your most humble and obedient servant has used frequently since purchasing it at a flea market in IIdabashi Tokyo many decades ago. I like the color it presents, the control it provides, and the compact size, but the teeth are little on the hard side as evidenced by a crack in one tooth. Togo steel is well-known for being on the brittle side.

The shumoku handle attached to the Togo steel saw is one your humble servant made from kiri wood with mulberry wood inserts and a black persimmon retaining wedge. The inserts keep the blade’s tang from wearing out the soft kiri wood, and the wedge makes it easier to remove the handle for transport. It’s fancier than necessary, but I had fun making it. Another way to secure a shumoku handle is with a dovetail wedge inserted from the side, but I don’t like the weaker nature of this style, nor the feel of the wedge in the hand.

Gentle Reader will notice that the straight tang of the shorter saw has been cut off (“bukkiri”) square by the original owner long ago, and that the back of the blade curves away from the cutting edge. This curvature is standard for rip saws.

The longer 355mm saw, by comparison, has a shumoku handle I made from tougher Japanese white oak with a more-or-less rectangular cross-section and is secured by friction alone.

The blade of the Takijiro saw is more-or-less straight, lacking the curve towards the end, and instead of the tang being straight it’s curved downwards in the direction of the teeth. This is not a standard blade converted into a gagari by chopping the tang short, but was planned to accept a shumoku handle from the time it was just a spark glowing in Takijiro’s forge, making it a dedicated, professional rip saw. Takijiro shaped this saw for me after one his master forged for a temple carpenter many decades ago, a craftsman I met at his workshop, and who gave me the opportunity to use, and fall in love with, his saw.

Please don’t tell my other saws I said this because they tend to be anthropomorphically jealous, and while saw cuts seldom make hearts bleed, they can make fingers fly.

Converting a Rip Saw to a Bukkiri Gagari

Gentle Reader can readily convert a standard Japanese rip saw into a bukkiri gagari by cutting the tang short and making a shumoku handle, as is the case of the shorter saw in this article. The longer style saw is not available new, although Takijiro has forged a couple of them over the years for our Most Beloved & Patient Customers.

While this article has been about dedicated rip saws, some craftsmen convert crosscut saws in the same way.

A safety warning is called for here, however, after all, they don’t call it the “nanny state” for nuttin. If you add a shumoku handle to a standard saw blade, be sure to at least cut off the pointy end of the tang. Otherwise, you’re likely to find your chest and/or arm leaking red sticky stuff compromising your color-coordinated woodworking togs, a simply devastating fashion faux pas.

Until we meet again, I have the honor to remain,

YMHOS

A bukkiri gagari rip saw This is one of a matched set of rip/crosscut saws custom-forged by Choujiro (Azuma-san) for a temple carpenter who never picked them up. Notice the curved back peaking towards the end, the golden temper discoloration typical of handsaws made in Eastern Japan, and the old-fashioned forge-welded iron tang. With a toothline length of 330mm and progressive teeth (smaller towards the tang), this is a serious saw for serious work.

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Japanese Handsaws: The Maebiki Ooga 前挽大鋸

A famous blockprint by Hokusai titled “Mount Fuji Seen from the Mountains of Totomi,” showing a crew of sawyers rip-sawing a timber into boards using maebiki ooga saws, one man on top and one underneath. Notice a third man to the left sitting under the timber sharpening another saw, perhaps his own or that of the fellow sitting in the background. A woman, probably the loving wife of the saw sharpener, has a baby wiggling around on her back trying to get a better view. She is no doubt waiting for her husband to pause his file work so she can deliver his lunch contained in the traditional furoshiki cloth depicted in her left hand. Some things never change with time or place, so she probably isn’t standing there silently, but I will leave the subject of the one-sided conversation to Gentle Reader’s imagination.

A society that puts equality—in the sense of equality of outcome—ahead of freedom will end up with neither equality nor freedom. The use of force to achieve equality will destroy freedom, and the force, introduced for good purposes, will end up in the hands of people who use it to promote their own interests.

Thomas Sowell

The name of this tool can be translated directly into English as “Front Pull Large Saw.” Kinda sorta almost hardly makes sense in light of the other tools that do the same job.

This tool is a large, relatively thick and heavy rip saw specialized for sawing logs into timbers and boards, but it can make various types of rip cuts in wood, sometimes pulled up through the kerf, and sometimes pulled down from below, as shown in the wood block print by Hokusai above.

Various timber and arborist’s crosscut saws have a gradually bent tang, while others have a cranked tang like the saw which is the subject of this article and shown in the photo above. Not seen in the photo is the tapered portion of the tang inside the stubby handle.

Although the scale may not be readily apparent from the photo, these handles are often quite large, perhaps 7~8cm in diameter and 15~20cm long, to provide a large bearing surface for two hands. This is definitively not a one-handed saw.

The best material for this type handle is said to be soft paulownia wood (桐) because it cushions the workman’s hands without becoming slippery when wet with perspiration, a common state for this hard-working tool.

Here a few links to YouTube videos of these saws in-use: Link 1 Link 2 Link3 Link 4 Link 5

Advantages

There are four advantages to this saw of which your humble servant is aware. First, while it is by no means a lightweight wood-gobbler, it does not require the long, clumsy, heavy frame of two-man saws, so it can be more easily transported.

Two sawyers using a frame saw to rip planks. A heavy tool and surprisingly difficult to control.

Second, it can be operated by a single craftsman.

Third, due to its wider, much stiffer blade, the maebiki saw tends to cut a straighter kerf with less effort than two-man frame saws can typically achieve.

And finally, while the strip of metal forge-welded to the edge and containing all the teeth is hardened high-carbon tamahagane steel, the rest of the blade is comprised of unhardened low-carbon iron.

This bi-metal construction technique is not only ancient, it was once standard procedure among all civilizations back when steel was comparatively expensive (not really that long ago actually). As a result, the maebiki ooga saw employs far less costly steel than that required to make a two-man frame saw.

In any case, as Gentle Readers and Beloved Customers with experience ripping wide boards are no doubt aware, using human bones, muscles and tendons to saw boards and timbers requires patience, and a lot of sweaty, hard work. Thank heaven for machine saws.

I own two maebiki oga saws, both purchased at flea markets in Japan in the 1980’s before collecting them became popular. They are currently in storage in the USA, no doubt sad and lonely in the dark.

Long ago I had them both professionally evaluated and learned that they were produced of iron and tamahagane steel sometime during the mid-Edo Period (1603~1867).

I had them professionally sharpened and, just for the heck of it, used one to square up a pine timber under the tutelage of an old-timer. An interesting experience but one I would prefer to not repeat. For you see, while the saw was simply quivering with excitement at having sharp teeth again and tasting fresh wood after many many decades of neglect, I fear I did not provide it the excitement it so desperately wanted, disappointing it badly. At the time, I thought I heard a mumbling issuing from its many gullets, something about me being a lazy bum… But of course, that couldn’t have been the case (シ)

After that I mounted it over the door to my workshop so it could at least imbibe the savory smells of fresh sawdust on a regular basis as it gazed down upon its domain. No complaints so far.

Despite, or perhaps because of, its unusual appearance, no saw I am aware of exudes a more powerful presence, or contains more internal focused energy, than the maebiki ooga saw. What think ye?

YMHOS

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Handsaws: Some Guidelines to Aid Precision

A famous wood block print by Katsushika Hokusai titled ” Mount Fuji Seen from the Mountains of Totomi,” one scene in thirty-six. With pre-big-bang Mount Fuji in the background, a group of four sawyers, and judging from the mother and baby in the foreground, probably including at least one family, are sawing boards from a huge timber on the very mountain where the tree was felled. Two men are sawing away with maeibiki ooga saws, one from above and another from below, while a third sharpens a saw underneath. Clearly, OSHA approval was not obtained for this working arrangement, oh my! They probably slept in the rough shelter erected at the left. A brutal, if scenic, lifestyle with abundant fresh air and fragrant sawdust.

Perfection is a necessary goal, precisely because it is unattainable. If you don’t aim for perfection you cannot make anything great, and yet, true perfection is impossible.

Leonard, The Outfit

Cutting joints connecting one piece of wood to another, such as mortise and tenon joints, bridle joints, dovetails, etc. using only handtools is not difficult, but most people find, at least initially, that executing them to fit together tightly without slop or unsightly gaps can be challenging.

The ability to routinely and quickly cut tight, workman-like joints with a handsaw is a critical skill for the professional that specializes in making limited runs of custom furniture and casework because including exposed joints not only sets his products apart from mass-produced dreck, but the apparent precision of those joints is a direct, long-term reflection of his standards of quality. And while it may not be a critical skill for the amateur who produces high-quality woodwork, it is nonetheless extremely satisfying, especially if the cabinets, furniture or casework he makes will remain in his house or with family where any poorly-fitting joints will silently laugh at him with “open mouths,” as the Japanese saying goes, over many years. Your humble servant loathes and fears such mocking whispers!

So, how does one go about improving one’s skill with handsaws thereby avoiding the sidelong glances and silent, but nonetheless snide, remarks of gaping joints? In this article your most humble and obedient servant will be so bold as to provide some guidelines I have shared with friends and Beloved Customers over the years, but which I have never before compiled into a single document. Please let me know in the comments below if these techniques prove useful.

The Saw

Of course, hand-cut joinery is accomplished using handsaws, tools that vary widely in quality and performance, so it is appropriate to begin this discussion with an explanation of the features a high-performance handsaw should incorporate.

In your humble servant’s well-informed opinion, the handsaw is by far the most difficult woodworking tool for the blacksmith to produce. Sadly, there are few skilled blacksmiths producing handmade saws nowadays, and while new companies producing pimped-out high-priced backsaws targeting amateurs have sprouted up, many of those exhibit performance inconsistent with the high prices their manufacturers demand. Imagine that….

But never fear, for below is a list of key things Gentle Reader should look for in a high-performance, professional-grade handsaw to be used for precision joinery.

The Plate

Whether Western or Japanese, the “plate” of a saw (the piece of sheet steel that comprises the blade) is its most important component. It must be adequately hard to resist bending and buckling, and so the teeth cut into it can be made sharp and stay sharp a long time, but not so hard the blade will crack or the teeth break off. This is a delicate balance. Sadly, most manufacturers err on the side of softer and duller. Sigh…

The best handsaws are made from plain high-carbon steel with a fine crystalline grain structure. Thus it has always been, and for good reason. Sadly, high-quality steel of this sort is difficult to procure nowadays.

Most of the new American and European manufacturers of backsaws, as well as all the Japanese manufacturers of replaceable-blade handsaws, make their saw plates from pre-hardened, thickness-sanded steel purchased in sheets or rolls, metal never touched by a blacksmith. This is a consistent and cost-efficient material that eliminates the need for blacksmithing skills, but it has a few serious limitations that negatively impact a saw’s performance.

In the case of mass-produced Japanese blades with the discolored, hardened teeth, after the plate has been stamped out with dies and a press, or cut to shape with a laser, the teeth are shaped by grinders, set is applied by machine, and the blade is passed quickly through an induction coil formed by two copper blocks charged with high voltage electricity, suddenly heating the teeth in a technique called “shock hardening.” The plate never slows down, and as the red-hot teeth exit the copper-alloy blocks charged by an induction coil, they pass through a coolant spray which instantly quenches them creating a hard, crystalline structure in the metal.

Most Western backsaws are made using similar materials and processes but without the induction hardening step.

210mm Dozuki saw hand-forged by Nakaya Takijiro, the ultimate handsaw for precision woodworking.

Taper Grinding

A high-performance saw’s plate will be taper-ground in at least one direction, with the plate made thinner at the back than at the teeth, providing extra clearance in the cut, increasing as the blade cuts deeper into the wood, reducing friction between wood and plate for a smoother cut with less effort, and reducing the risk of buckling.

Handmade Japanese handsaw blades are of course double-taper-ground, as once were all quality Western handsaws too, but sadly neither replaceable-blade Japanese handsaws nor modern Western backsaws are taper-ground to any degree. John Disston would puke.

Unfortunately, too many modern users of handsaws, wandering in an Instagram world, have become entirely inured to terminal Chinese Logic, such that most are incapable of even considering qualities they can’t instantly infer (correctly or not) from a photograph on the internet. These confused souls deserve our pity.

Gentle Reader would be wise to place his priorities regarding performance above outward appearance, because a prettily-finished exotic hardwood handle, a beautifully sanded/polished finish on a sawplate, and even an eye-catching etched brand contribute neither diddly nor squat to a handsaw’s job of making precision cuts.

Hammer Tensioning

Hammer tensioning is an ancient technique whereby the sawsmith or saw sharpener rests the plate on an anvil and taps the plate with his hammer creating small dents in specific areas. Each tiny dent deforms the metal making the plate slightly thinner at the point of impact while at the same time displacing a corresponding amount of metal away from the point of impact. Being constrained from expanding as much as it wants to by surrounding metal, the accumulated strain of many dents creates internal stresses that tend to make the saw blade wider and longer. Taken too far, these stresses will make the sawplate buckle or oilcan, but if done just right, for all practical purposes the sawplate will remain flat and stable.

Why bother with all this noisy hammer tapping? Clearly Gentle Reader is exceptionally perceptive to pose this question, and accordingly your humble servant quivers with joy at the prospect of clarifying an elegant and ancient mystery, one that is still employed to good effect in high-quality modern circular saw blades as I learned during recent meetings in Nagoya with three of Japan’s largest circular saw blade manufacturers.

So here’s the reason: As a sawblade heats up due to friction in the cut, the metal of course expands, but not uniformly over the blade’s entire surface. This differential heating and resulting differential expansion causes a sawplate that has not been hammer tensioned to temporarily warp, increasing friction in the cut even further, and making the cut wander thereby ruining the precision of the cut, and in the worst case, causing the saw to bind and even buckle betimes kinking the poor unfortunate blade.

The residual stresses produced in a saw’s plate through proper hammer tensioning counteract and cancel out stresses produced in the sawblade through friction heat thereby preventing the plate from buckling, excessively warping, or oil-canning, with the result that the saw will cut straighter and cleaner with less effort even as it heats up.

I don’t know who invented this subtle technique far back in the mists of time, or where, but it is genius-level engineering.

The better-quality Japanese replaceable-blade handsaw makers have taken a page from the circular sawblade manufactures and run their sawblades through a pair of opposed steel rollers which induce stresses in the steel similar to hammer-tensioning by hand. I may be wrong, but I am unaware of any modern Western backsaw makers that either hammer-tension or roller-tension their sawplates, but instead rely solely on the stiffness of the applied back to prevent buckling. Once again, JD would hurl.

Another benefit of hammer-tensioning, and one Gentle Reader can ascertain easily by examining a saw blade in person (but without the back installed) is that the internal stresses resulting from hammer-tensioning make the sawblade much stiffer than it would normally be without adding metal or weight. You can observe this phenomenon yourself by holding a panel saw’s blade by the narrow end with one hand extended out at arm’s length and examining the blade’s sag. A hammer-tensioned blade will sag significantly less than one that has not been hammer-tensioned.

Another easy test for hammer tensioning applicable to panel handsaws is that of bending the sawplate and tapping it with a fingertip producing a musical note that can be varied by changing the degree of bend in the sawplate. In fact, believe it or not, the handsaw was once a popular musical instrument in some quarters in the USA, with all the major saw manufacturers producing specialty musical saws (sans teeth).

In summary, a properly hammer-tensioned saw will be stiffer, will cut straighter, can be made thinner and lighter, and will require less force to operate for the amount of sawdust generated.

The hand-cut and hand-filed teeth of a 210mm Dozuki saw by Nakaya Takijro. The small dings visible near the chin of the blade are the marks left by hammer tensioning.

Teeth

Tooth types and preferences in handsaws vary so widely that little can be said that applies to all. However, Gentle Reader should consider the following when evaluating a handsaw to be used to cut precision joints.

First, assuming the teeth are the desired shape and size and progression, they should be uniformly and extremely sharp, indeed, sharp enough to cut you if touched carelessly. If you place the palm of your hand gently on the line of teeth, you should feel the little buggers trying to grab your skin. Not just one or two of the vicious little teeth should frantically try to eat you, but all of them in contact with your hand should seem eager to nibble because each tooth is either a frightfully-sharp, pointy little knife, in the case of a well-made and expertly sharpened crosscut saw, or a razor-sharp little chisel, in the case of a rip saw. And of course, a well-made and sharp saw is always eager to cut anything and everything it can get its teeth into. Just ask it.

Unfortunately, the teeth of most of the new crop of Western saws made nowadays are, in my experience, poorly sharpened and in need of TLC before they are useable. I say this as someone that prefers Western handsaws for some tasks, sharpens his own saws by hand, has purchased, collected and tested both new and antique Western handsaws over the years, and continues to use the better of them regularly.

In the case of most woodworking tasks, sawteeth need to have some degree of “set” to make the sawkerf wider than the thickness of the plate to reduce friction, binding, and buckling. Indeed, to compensate for a missing taper-grind and hammer tensioning, most modern Western saws are made with excessive amounts of set. This matters because all the extra wood the sawblade must cut to accommodate this extra set is wasted effort turned into sawdust that does nothing to improve speed or accuracy. Therefore, a good handsaw will have no more set than absolutely necessary to get the job done.

This means, of course, that one needs different saws with different set and different tooth styles for different types of cuts in different types of wood. It makes a difference.

On the other hand, if Gentle Reader uses handsaws solely to burn calories, the aforementioned points should all be studiously ignored. (ツ)。

The teeth of a 210mm Hozohiki rip saw hand-forged by Nakaya Takijiro. The hand-filed steel back finished in traditional burnt silk is also visible at the top of the photo. These teeth are specifically designed to meet the demands of professional Japanese luthiers working in exotic hardwoods.

If Gentle Reader is in need of a high-quality hand-forged saw, you may want to consider those made to C&S Tools’s specifications by one of Japan’s last remaining master sawsmiths, Nakaya Takijiro. You can see some of his products at this link.

A 210mm Hozihiki rip saw hand-forged by Nakaya Takijiro from White Label steel No.2. This saw, and especially its teeth, are specifically designed for cutting precision knock-down joints in the hard, exotic woods, such as ebony and rosewood, that Japanese luthiers use to make shamisen, harps, lutes and other traditional musical instruments.

Using a Handsaw to Make Precision Cuts

The overarching guiding principles in using handsaws to make precision cuts are the following:

  1. The Saw: Use a high-quality saw with the features described above. If you don’t yet own such a saw or can’t afford one, and even if you do, educate yourself in blade sharpening, applying set, and in the techniques of straightening sawplates so your saw will achieve its maximum potential performance;
  2. Layout: Layout the cut so there is no confusion about where it starts, where it continues, where it ends, and the angle of the cut. Whenever possible mark cuts in such a way that the sawblade can positively index itself. This means that the sawteeth will fit into the layout line without you having to guess or use a magnifying glass. Marking knives and marking gauges with sharp cutters can produce such layout lines better than pencils and pens. If there is any chance of confusion, include marks in your layout indicating, for example, the side of the line to cut to and where to stop;
  3. Arrangement: Arrange, support and align the workpiece, your body, and your eye to produce only straight cuts with every single stroke. This point is relevant to item 4 below;
  4. Make of Thyself a Machine: More details below;
  5. Attention: Pay attention to make every single stroke accurate;
  6. Stop & Correct: The instant a stroke goes astray or the cut wanders even a little, stop sawing, figure out why, and make corrections, dammit. Not ten strokes or even two strokes later, but instantly. This requires concentration and iron-handed control of your inner squirrel.

Layout

Spend the time to do layout and marking properly, because confusion and uncertainty during the cut will result in reduced mental focus, and often, poor precision. A solid, well thought-out plan combined with a sharp marking knife, a sharp marking gauge, and an accurate, hardened steel square help to make good lines yielding good cuts.

Arrangement

In order to achieve No.4 in the list above, “Make of Thyself a Machine,” you should spend the time and develop the habit of securing the workpiece at a height and angle that will aid the imperfect human body to make perfect cuts. In my case, this means checking the angle of the dangle and using a vise, C-clamp or a butt-clamp to hold the wood down. It also means stopping work to rearrange the workpiece when necessary. I recommend you try various methods to find which one works best for you when making each type of cut.

In most cases, I like to make gravity my friend by positioning and securing the workpiece so the plane of the cut is vertical. My workbench is level, so either Mark-1 Eyeball or a square usually suffice to confirm alignment, but a small spirit level is sometimes helpful too.

For example, when cutting the tails of dovetail joints, I secure the board in a leg vise, and tilt it so the cuts for half the tails are plumb. When done making those cuts, I next rearrange the board in the vise so the opposite sides of the tails are in the vertical plane, and cut them. Perhaps this is overkill, but it is a habit that helps me to consistently make precise cuts with less damage to brain and eye.

The body must be aligned with the cut to avoid stresses and strains from misaligning “The Machine.” A comfortable position is therefore necessary.

If at all possible the eyeball must be positioned so it can see both sides of the cut to not only guide the cut, but quickly detect a wandering cut, because we all tend to get lazy partway through a cut and stop looking, allowing our inner squirrel to chase after nuts with predictable results.

3 sawyers sawing lumber from a timber, one on top, one from below, and another carrying a saw, probably one he has freshly sharpened. At the right, a carpenter with pipe and tobacco pouch hanging from his waist sash (obi) is using square, sumitsubo, and sumisashi ink pen to do layout on the end of another timber. The mother hens at OSHA would simply be clucking with disapproval if they saw this scene in the flesh.

Make of Thyself a Machine

The title of this section is not intended to suggest Gentle Reader should surgically install bionic parts or change their racial and gender pronouns listed in social media to “Synthetic Person.” (シ) No indeed, nothing so “progressive” is necessary (BTW, what is the politically-correct pronoun for a cyborg: Clank or clunk?). Rather, this phrase refers to a combination of techniques that will help even non-cyborgs overcome the erratic tendencies of flesh, sinew and bone in order to produce more consistent, precise results with a handsaw.

To make a straight cut, the sawblade must travel within a single vertical plane during both the cutting and return strokes. While obvious, this is where nearly all people screw up, always when learning how to use a saw, and in most cases, forever. But we can do better.

If Gentle Reader will pay close attention when making a cut with a handsaw, you will notice that the hand, and consequently the saw handle, tend to move in an arc right and left in a horizontal plane as seen from above. This movement is a result of naturally flexible linkage between hand, arm and shoulder that transmits the force generated by the muscles to the tool handle. We must control the limits of this “flexibility” if we are to make a straight cut. We can do this by making of ourselves a “machine.” It’s almost as easy as the “tricky part” of the Big Fig Newton dance.

How to do this? Let’s take it step by step. First, grip the saw firmly but not too firmly. The old swordmaster’s instructions apply: Hold the handle like a small bird: Too loose and it will fly away; Too tight and the little bird will be crushed. This grip is important because if you hold either sword or saw too tightly, your muscles and tendons will lock up and you will be unable to form the consistent machine necessary to accurately control the tool’s movement.

The second point to understand about grip is that, while all of the fingers of the hand may touch the saw’s handle, apply your gripping force through the index finger and thumb only (in the case of straight-handled Japanese saws), such that the saw can almost freely pivot around a line drawn between these two fingers and through the handle.

Next we need to align the sawplate with the cut. To do this, arrange the workpiece securely, and assume a relaxed stance facing the layout line you will be cutting to on the workpiece with eyeball centered on the layout line. Then, with saw held in the relaxed swordsman’s grip you intend to use during the cut, hang it loosely down alongside your leg. Stand back from the line and adjust your stance so the plate of the hanging saw is in the same plane as the the intended cut line, but when fine tuning your stance (this next part is important) don’t move your hands, arms, shoulders or hips to align the sawblade with the plane of the cut, but rather move your feet. This is approximately the ideal angle between your body and the intended cut.

Next, without changing position, center your dominant eye on this plane again.

Then, being careful to avoid hitting anything (especially stray bench dogs or kitties), gently but freely swing the saw forward and back 90˚inside this same plane. If your hand or your saw touches your leg, or your elbow hits your side, then adjust your stance so they don’t. The saw must swing freely with the sawblade in the same plane as the cut, with your shoulder joint, elbow, wrist and eye all centered in the same vertical plane.

Next, swing the saw up into the cutting position, and move it back and forth as if cutting wood. Your grip should still be loose (remember the little bird), and the saw should continue to move in an invisible plane centered through your shoulder, elbow, wrist, sawblade, and the layout line. Now pay close attention to the movement of your hand as it goes forward and back; Is it still traveling a little right and left in a horizontal arc? It probably is, my cyborg friend.

Now, while maintaining the stance established earlier, step forward enough to actually make a test cut. Start with a few itsy bitsy teeny weeny little cuts in a test piece to establish a stable beginning for the kerf. Then begin cutting in earnest, but while doing so, pay attention to the movement of your hand. Is it still scribing right and left horizontal arcs in the air? If it is, then on the cutting stroke, in the case of a Japanese pull saw, or the return stroke in the case of a Western push saw, reposition your stance so the inside of your elbow lightly brushes your side. Then adjust your head and eye to match. This contact between elbow and side is an important target point that will help position one end of each stroke, essentially creating rails for the machine to operate within. Remember the feeling of this contact.

When you make the cut, you will notice the sawblade is still scribing small arcs right or left. This fine movement persists because the wrist joint is too stiff preventing it from rotating slightly to keep the sawblade moving in a straight line, with the result that the saw’s handle is either rotating too much or too little, too soon or too late, causing the sawblade to deviate from the plane of the cut. It is impossible to reduce this out-of-plane deviation to zero, but you can cancel out most of it by maintaining your swordsman’s grip, loosening your wrist and actively rotating it in anticipation of this right-left arc. Yes, you can do it.

Your shoulder, elbow, flexible wrist and hand, supported by the rest of your stone-stable body, and watched over by your unrelenting Sauron-like eye, now form a machine with invisible rails that will move the saw in a vertical plane almost perfectly aligned with the plane of the line to be cut (perfection is unattainable and unnecessary).

One last point. It is essential to realize that the saw cuts because it is sharp and wants to make sawdust, not because of thy mighty arm, Oh Lord Cyborg. This is another phrase worthy of a forehead tattoo if you have any room left (ツ)。When we actively apply much force to a saw, especially if the teeth are dull, it will resist our boorish behavior, stumble over the woodgrain, clog with the sawdust, and almost always wander out of the plane we want to cut in. To avoid giving offense, please ensure your saw has a true plate and sharp teeth, do your layout, make the machine, start the cut, then get out of the saw’s way, dammit, and patiently and carefully watch it make sawdust. Don’t be too proud, Lord Cyborg, because, after all, you are the weak link.

Making the machine takes practice and time, but once you have figured it out, and know how it should feel, you will develop muscle memory. It’s like driving a car: Every modern car is different, but every modern car is the same.

BTW, there are various saw jigs one can make and use to enhance one’s cybernetic capabilities which we will consider in future articles.

Pay Attention

Until the necessary muscle memory has permeated all the way to your bones, don’t forget to pay attention to every single stroke you make with your saw. This is exactly the opposite of human nature that wants to keep on cutting like a honey badger going after the fixins for a barbecue ground squirrel sandwich until the cut is finished. But when training oneself to make highly precise sawcuts, it is best to concentrate on each stroke, making sure it doesn’t wander. After all, it is the accumulation of many accurate small cuts that results in an accurate final cut. Likewise, it only takes a few inaccurate cuts to result in a sloppy final cut, so please pay attention.

Once you have become the machine and developed the necessary muscle memory the process will go very quickly indeed. Sadly, this fine muscle memory is not a permanent thing, but once learned it can be quickly remembered.

Stop & Correct

While sawing away, if you notice your cuts are going astray, stop and figure out why. Is your position good? Is your eyeball where it should be? Is the sawblade aligned with the plane of the cut? Is tension released from your wrist? Is your elbow brushing the same place on your side with each stroke? Is the machine operating faithfully or are the invisible rails bent? Are the teeth dull? Are you applying too much pressure? If things aren’t right, stop the cut, figure out why, and make corrections NOW. Don’t wait.

This self-control is possibly the most difficult task in making accurate cuts with a handsaw, but also the most critical to gaining skill. Failure to do it will result in either learning bad habits, or in delays in correcting the ones you already have. BTW, everyone has bad habits they need to work on, including YMHOS.

The Essential Oilpot

Unlike quadruple-distilled, aged in ancient bog-oak unicorn wewe, wood is not a friction-less material. To make things worse, a saw kerf usually becomes “hairy” with loose wood fibers sticking out into the kerf increasing friction in unpredictable ways. And the cherry on top is sap and resin residue found in all wood and which increases friction further.

This friction not only heats the sawblade, possibly warping it and wasting our energy and time, but more importantly it makes it more difficult to control the sawblade in the cut, often making our precision suck big donkey donuts. How to counteract this friction? The classical Japanese solution is the Oilpot.

This tool has long had counterparts throughout the world, and it’s as valuable now as it was six thousand years ago. If you want to use handsaws with high precision, you need to make yourself one. You will be impressed with the difference. Nuff said.

The Two-handed Pistol Grip

When I was a young carpenter working commercial construction, I had a foreman named (I kid thee not) Jack Frost who was offended that God did not give him a tail, especially when working on high scaffolding. Gentle Reader may agree that a fifth appendage could often be handy, despite the fashion compromises it would “entail.” However, consistent with human physical limitations, the fact remains that most joinery saws are operated using either one hand or two, but not by tails.

The discussion above is relevant to all saw grips, but is focused mostly on the single-handed grip. However, just to be thorough, your humble servant would like to describe another style of grip used by some Japanese craftsmen, one your humble servant calls the “Two-handed Pistol Grip.” As the name suggest, instead of gripping the saw in one hand off to the side of the body, the saw’s handle is gripped first by the dominant hand in a pistol grip with the index finger extended along the handle’s side. The index finger of the off-hand is then extended alongside the grip parallel to and opposite that of the dominant hand, and the remaining fingers wrapped over those of the dominant hand.

The sawblade is then operated inside a plane going through the chest and centered on the user’s nose, often quite effectively counteracting the right-left arc tendency. The “swordsman’s grip” is essential to using this technique effectively.

This technique is not good for powerful cuts, but works well for shallow, precise cuts.

I apologize that, despite popular demand, this article lacks clean diagrams and pretty pictures of your humble servant exhibiting these techniques while wearing his sexy blue sequin bikini and famous aluminum-foil alien mind-ray dispersal cap (with curly copper wires and red fringe). But, as the saying goes, “Life is a bowl of cherries, mostly pits.”

Until we meet again, I have the singular honor to remain,

YMHOS

Another construction jobsite possibly non-compliant with OSHA rules.

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Please share your insights and comments with everyone in the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, or thuggish Twitter and so won’t sell, share, or profitably “misplace” your information. If I lie may all my sawteeth shatter.

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Japanese Handsaws: The Twins

The Ripsaw member of the Twins. Notice the curved back peaking towards the far corner, the golden temper discoloration typical of handsaws made in Eastern Japan, and the old-fashioned forge-welded iron tang. With a toothline length of 330mm and progressive teeth (smaller towards the tang), this is a serious saw for serious work.

Communism is the opiate of intellectuals [with] no cure except as a guillotine might be called a cure for dandruff.

Clare Boothe Luce

his article is a show-and-tell about a matched set of custom-forged handsaws which have been your most humble and obedient servant’s trustworthy companions in the noble profession of making sawdust for many years.

A Bit of History

The archaeological record suggests that, at least in areas of the world where rusty remains have been excavated, the standard metal handsaw in ancient times had rip teeth only. As evidenced by the superior mental powers Gentle Reader exhibits, Woodworkers have historically been extremely intelligent people, so no doubt many sawyers, carpenters and joiners back in the mists of time independently discovered that filing (or stoning) their sawteeth to an acute bevel angle and alternating the direction of the bevel made the saw cut much faster and with less effort across the grain (i.e. crosscutting).

With this discovery, the crosscut saw was born, and thenceforth has been a worthy servant to its masters and a good companion to its elder sister the rip saw.

In modern times with the proliferation of inexpensive (and dangerous) circular saws, rip handsaws have become as rare as selfless tax collectors, but the combination of a rip saw for making cuts parallel with the direction of the grain of the wood, and a crosscut saw for making cuts perpendicular to the grain of the wood has been common-sense among those who value accuracy and efficiency at least since the proliferation of carbon steel saws.

The Twins

Some decades ago while working as a carpenter, your humble servant realized he needed a set of larger rip and crosscut saws for fabricating joints in timbers. The search resulted in the purchase of several saws, but the set described in this article are the two I have come to rely upon for such tasks most.

Both saws were hand-forged 70~80 years ago in Sanjo, Japan by a saw blacksmith named Azuma with the brand-name of Nakaya Choujiro (中屋長次郎), a venerable name in Eastern Japan. The grandson of this blacksmith is still producing saws in Sanjo today, including the Seijiro brand ryouba saws we carry. Nowadays nearly all of his production has shifted to short saws used by luthiers.

I found these saws in a tool store in Tokyo which is now defunct due to the owner’s inconvenient relocation to the big lumberyard in the sky. At the time of purchase, the store owner informed me they were originally commissioned by, and custom forged for, a Miyadaiku (temple carpenter) in Arakawa Ward of Tokyo who had moved on to sorting boards in a more exalted clime without picking up these sawblades (no handles), leaving them sad and lonely in a cabinet hidden behind buckets of paint and roofing materials.

I get misty remembering their joy at being rescued after languishing so many years in darkness…

The Rip Twin aka Bukkiri Gagari

The saw in the photograph above and at the top of this article is a large kataba (single-blade) rip saw with aggressive, progressive-configured teeth called a “bukkiri gagari.”

“Bukkiri gagari” is a name used for large rip saws with this style of handle. The word “gagari“ refers to a large rip saw. The word “ bukkiri” probably means “chopped” or “cut down,” referring to the shortened tang.

The pointed tang, typical of handsaws intended to be fitted with a straight in-line handle, was bobbed at the time the saw was forged, evidence that it is not a conversion, but was intended to be a bukkiri gagari when just a twinkle in Grandfather Choujiro’s eye.

The large brownish-orange discoloration seen on the blade is neither corrosion nor a shadow due to poor lighting, but a remnant of the heat-treating process common to saws forged in Eastern Japan, more evidence of quality handwork.

The blade’s length measured from tip to the beginning of the tang is 425mm (16-5/8″). The cutting edge (teeth) measures 330mm (13″), making it a 1-shaku 1-sun blade a slightly unusual length. The blade’s overall length measured from the tip of the exposed tang to the tip of the blade is 625mm (24-5/8″). It measures 130mm (5-1/8″) at the widest point at the tip of the blade. The back of the blade has a slight curvature away from the cutting edge as is standard for larger rip saws forged in Eastern Japan.

A closeup of the tang of the bukkiri gagari member of the team. Sorry for the poor focus, but the hand-carved signature of Nakaya Choujirou (中屋長次郎) is plain to see. Some people prefer to jamb the handle on permanently, while I prefer the options a wedged handle provides. The wedge can be inserted from front or back, top or bottom, changing the angle of the handle and its distance from the cutting edge. The forge-welded connection between iron tang and steel handle is more visible in this photo. This detail is coveted by aficionados of Japanese saws as witness of quality handwork.

I made the handle from Japanese White Oak stained mahogany color. It measures L270mm x w38mm x t30 (10-5/8″ x 1-1/2″ x 1-3/16″).

No doubt Gentle Reader is familiar with the more common Japanese handsaws with straight, softwood handles. This style of handle is called a “shumoku tsuka” 撞木柄 (shoe/moh/ku/tsu/kah) and is attached to the blade’s tang at an angle.

A shumoku is a wooden mallet used to strike bells in the Buddhist religion. I don’t know why this word is used for a saw handle; No one I have asked has been able to provide useful insight.

The shumoku handle can be attached to most any Japanese sawblade with a straight tang. It has several advantages. First, compared to the standard long handle attached in-line with the tang, it makes the saw much shorter in length and therefore handier for working in tight spots. This is especially useful when making vertical cuts from below for joints in the ends of large timbers resting on sawhorses or during erection where a long handle would get in the way.

The second advantage of the shumoku handle is the fact that, when combined with the stiffer blades of large rip saws, the user is better able to bring the stronger muscles of legs, back and both shoulders into play for more powerful cuts, an ergonomic principle similar to the thumbhole handle once common in Western handsaws.

The stance this handle makes possible also provides more leverage (greater moment couple) when cutting in tight situations and at unusual angles than a longer, straight handle can. This last factor makes the bukkiri gagari saw most valuable IMHO.

The Crosscut Twin

This is the crosscut member of the Twins. Also made by Choujiro with a forge-welded tang, it was forged back in the day as a matched set, and like it’s rip sister, it’s “juissun” in length with a toothline of 330mm (13″) long. The teeth are not progressive. Notice the curvature to the back which is the approximate inverse of the curvature of its twin the bukkiri gagari saw shown above. Subtly beautiful.

The crosscut member of this dynamic duo is also a kataba 片刃(single-edge) saw with a custom-made but more ordinary straight handle.

It’s overall length is 845mm (33-1/4″), with 420mm (16-9/16″) of that being the blade extending past the handle. The blade is 125mm (4-15/16″) wide at the tip.

The cutting edge portion of the blade matches its companion at 330mm (13″), so it too is a “Juissun” saw, meaning 11 sun.

It too has a beautiful curvature to its back which in this case is directed towards the cutting edge instead, giving it a diligent posture. As is the case with all matched sets forged by the same blacksmith (at least in Eastern Japan) the curvature of the back of each saw is the inverse of its partner so that they nest neatly against each other all lovey dovey. Although these cosmetic details have little if any practical purpose, Japanese shokunin are unreasonably fond of these matched saws, as am I.

Of course, the handle is approximately the same length as the the blade (not including the tang), and oval in cross section measuring 30 x 35mm x 425mm (1-3/16″ X 1-3/16″ X 16-3/4″). We will discuss how to make this type of handle in a future article.

Your humble servant made this handle long ago from a piece of scrap Akita Sugi cedar (cryptomeria), wrapped it tightly with copper wire at the mouth end to reinforce against splitting, applied a dab of solder to lock the wire in-place, and finished it by rubbing the wood with a tool called an “uzukuri” made from skinny but hard plant roots to partially remove the softer summer wood leaving an excellent, textured surface that won’t slip no mater how wet with sweat it becomes. I love Akita Sugi.

Gentler Reader (may the hair on your toes ever grow long!) may be wondering why one would use a short, sideways handle for a rip saw but a long straight handle for a crosscut saw. An excellent question indeed and further evidence of your superior intelligence!

Some crosscuts in timber work benefit from a longer reach. But more importantly, while the longer handle provides less power than the shumoku handle, it provides more control, essential for precise crosscuts. The way it was explained to me is that the large bukkiri gagari rip saw is used up close to the face and “guided by the nose,” while the large crosscut saw is guided from further away by the eye. Give it a try and you’ll see what I mean.

Although I haven’t used these saws professionally for far too long, I had the teeth sharpened and plate tuned a few years ago by a famous blacksmith and saw sharpener named Nakaya Takijiro located in Kawagoe.

In one or two of the photos you may detect the little marks his tapping tapping tapping hammer left on the blade when he trued and corrected it. No, he didn’t straighten it, but he induced internal stresses to relieve some oil canning that had existed from Choujiro’s forge. He also made other subtle stress adjustments with his little hammer that made the saw track straighter and smoother with less friction as it heats up. What a difference it made! He is literally a genius with a sawblade.

The blacksmith’s hand-cut signature on the crosscut saw: “Nakaya Choujiro.” The blade was shaped and tapered in thickness by hand using a “sen” scraper, as evidenced by the visible marks. Close observation reveals that the soft iron tang is not electronically welded to the blade as has become SOP post-WWII, but is forged welded, a technique saw connoisseurs greatly appreciate. Sadly, most of the surface corrosion occurred before your humble servant rescued this excellent saw from durance vile.

I don’t use these saws much anymore, but I enjoy taking them out of their protective wrappings once or twice a year to clean and oil them, catch up on news, and sing a song of sawdust together. They love to sing.

I hope you found this little show-and-tell amusing. I have other unusual saws I will introduce in future.

Until then, I have the honor to remain,

YMHOS

If you have questions or would like to learn more about our tools, please click the see the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

Please share your insights and comments with everyone by using the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, or thuggish Twitter and so won’t sell, share, or profitably “misplace” your information. If I lie may the teeth on my saws all snap off.

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The Mystery of the Scratched Blade

Redwoods

The wiser a man is, the more he stands ready to be educated.”

Joe Abercrombie, A Little Hatred

In this post your humble servant will offer some advice that, if followed, will save Gentle Readers time, money, and wear and tear on their valuable woodworking tools. These are not original techniques; I stole them long ago from professional woodworkers in Japan. Wise Gentle Readers will be as bold.

But first we must solve another mystery, so prepare to enlist the help of your inner Agatha Christy.

As with the other mysteries we have examined, this one involves no dark and foreboding alleys shrouded by ominous mist and concealing footpads with rubber knives, or bottles of vintage Tabasco Sauce spiked with arsenic. Indeed, nothing so mundane.

Investigating the Scene of the Crime

Last December your humble servant received an ordinary Christmas Card from an old friend, probably a “re-gift.” It was unusual in that it contained brick dust. The sender of the card was my old friend Woody, a charming fellow, diligent woodworker, amateur thespian, and possible alcoholic. Gentle Reader may recall this gentleman from a previous adventure I wrote about called The Mystery of the Brittle Blade. Wait a minute! Now that I think about it, you went with me to visit Woody at that time and actually helped solve his little mystery. Thanks for your help!

BTW, the screenplay for that story is currently being reviewed by top producers and directors in Hollywood, at least that’s what the movie promoter I met at Krispy Creme Donuts here in Tokyo promised (ツ). He seemed like a reliable guy so I paid for his donuts and coffee.

Obviously, Woody’s dusty Christmas Card was a subtle cry for help so I went to visit him in his rickety, leaning workshop during my international travels last January. When I got onto the airplane I was shocked to find myself only one of approximately sixty travelers on a commercial flight that normally carries 350+ passengers, so I reclined across the center aisle of seats in cattle-class and slept like Nero after a night on the town.

Gentle Reader may recall Woody’s shop from the visit we made there together. Yes, it’s, still cold and dark and filled with the pungent funk of his faithful mutt Stinky.

Upon entering his shop I found Woody collapsed on the floor, an empty tequila bottle in one hand and a shiny bronze No.4 smoothing plane by Lie-Nielson in the other blubbering like a fool and muttering something like “Death, a necessary end, will come when it will come.” Woody ain’t much of a scholar but he has a romantic soul that sees every difficulty in life as Shakespearean in nature.

Seeing that my friend would be of no help in solving this mystery, I left him on the floor to practice his lines while I began my investigation of what, judging from the source material he was reciting, could only have been caused by something akin to Brutus’s betrayal.

The obvious first clue was his No.4 smoother, so I pried it out of his paws, dried the tears he had dribbled all over it, and observed a series of deep, uneven scratches on its sole, more or less in line with its the long direction. Whereupon, I twirled my white mustaches like an older, more handsome Hercule Poroit, and asked myself the following questions:

Question 1: What could have possibly created these scratches? Had iron pixies been using Woody’s beautiful plane to shave bricks?

A quick investigation of the workshop revealed several suspect bricks, but no signs of iron pixies at play. I remembered seeing Woody use these same bricks to brace the legs of his combination router table and barbecue betimes (he makes wonderful barbecued pork ribs, marinated in a whiskey sauce, BTW). I concluded it unlikely that either Woody or pesky pixies would have used this valuable plane to shave bricks at the unthinkable risk of disturbing a delicate combination tool (router table/barbecue) of such importance.

As I considered the wood Woody had been working, another question popped out of my brain like an egg from a hen:

Question 2: Is there anything that grows naturally inside a tree that is harder than a handplane’s sole and large enough to have caused such deep scratches? And if they do exist, could these particles have been maliciously concealed inside the growing tree by compadres of the shambling horde of 6-armed, green-skinned, Fanta-guzzling aliens that follow me everywhere? BTW, If you have seen these aliens, please send photos!

I next removed the plane’s blade, which was made of a tough and difficult to sharpen metal called A2, developed for making dies and other industrial components, and checked its condition. As suspected, the edge was not just deadly dull, but exhibited dents perfectly in-line with the deepest scratches in the plane’s sole. Egads! The thlot pickens!

Of course, Gentle Reader is aware that many varieties of wood contain hard silica particles that can wear out tools and quickly dull cutters, but they are seldom large enough to create deep scratches of the kind I saw on Woody’s plane’s sole. Hmmm.

Question 3: If these hideously-hard particles did not grow inside the tree, and were not concealed inside the tree by aliens, exactly how did the infernal particles that made these scratches come into contact with Woody’s pretty plane?

To make a closer visual inspection possible, I recovered my magnifying glass and deerstalker hat from my truck parked in Woody’s beer can-cluttered driveway.

Could the damage have been caused by nails, screws or staples left in the wood? Perhaps, but the appearance of the damage to the blade would have been different.

Pixie toenail clippings? Happens more often than we realize.

A tiny fragment from a divorce lawyer’s heart? Certainly any piece of such an organ would be harder than stellite, but being a fragment of a microscopic organ, such particles are harder to find than an honest politician in Shat Francisco.

“No,” I confidently declared; The culprit was harder than all these substances, more insidious than even Murphy’s pointy purple pecker, a substance all around us, one we often ignore. Rejoice Woody, for the mystery is solved!

Dust & Grit

Logging Redwoods in Humbolt County California, 1905

Politics and journalism aside, we live in a dusty, dirty world, and although the steel in your tool blades is very hard, ordinary dust and dirt contain plenty of particles much harder. I guaran-frikin-tee you that collision with even a small particle of mineral grit embedded in the surface of a piece of wood can and will damage a blade’s cutting edge.

You may believe the damage is minimal and of little concern, but every time your blade becomes dull, you must resharpen it. Every sharpening session costs you time pushing the blade around on stones, time not spent cutting wood. And sharpening turns expensive blades and stones into mud. This is time and money lost forever.

And the abrasive action of dirt and grit embedded in wood is not hard on just chisel blades, plane blades and the soles of steel planes, but is even harder on sawteeth and wooden planes.

And the damage is not limited to just your handtools either. Take a closer look at the steel tables of your stationary equipment such as your jointer or tablesaw. Unless they are new, you will find scratches. Has that purple pervert Murphy been smokin dope and humpin sumpin on your jointer’s bed when you weren’t lookin?

Nay, Gentle Reader, supernatural causes aside, and unless you have been dismembering the bodies of divorce lawyers in your workshop, these scratches are clear evidence that the wood you’ve been working is neither as clean as it looks, nor as clean as it should be. You’ve gotta do something about that.

Ruba Dub Dub

So what can you do about damaging dust and grit? Strange as it may seem, the simplest and surest way to get rid of dirt and grit is to follow your mother’s instructions about cleaning the bathtub: Simply wash it with soap, water and a wire brush, followed by a rinse.

Bet you never thought of washing wood before have you?

The idea is to wet, scrub with a wire brush, and quickly rinse the dirt and grit off the wood, not to make the wood soaking wet, so none of that “rinse and repeat” nonsense, and don’t get carried away with the water hose. A bit of dishwashing soap or washing soda mixed in the water bucket will help lift out dirt and grit.

Don’t forget to pat each board down immediately afterwards with clean rags to remove surface water. Then separate each board, rest it on stickers on-edge out of direct sunlight, and allow time and circulating air to dry it.

Remember to wet both sides of each board to minimize warping. And don’t soak a lot of water into the ends.

Disclaimer: Rubba-dub-dub is not well suited for thin material or laminated wood products that might easily warp, or delaminate, or if you are in a hurry, or if you lack adequate space to properly air-dry the wood. 

Whether you wash the wood with water or not, be sure to do at least the following two steps on every board before you process it with your valuable tools.

Scrub Scrub Scrub

If you can’t wash the boards, use a steel wire brush to dry-scrub all the board’s faces both with and across the grain. Yes, I know it makes the surface rougher. Tough pixie toenails. Scrubbing with a stiff steel brush is extremely effective at removing dust, dirt, embedded particles of grit, and even small stones from long grain. Give it a try and you will both see and smell the dirt and particles expelled. Pretty nasty stuff sometimes.

Saw Saw Saw

Second, and this is supremely important, before planing a board either by hand or using powertools, saw 2~3mm off both ends. This is why you have that circular saw with the carbide-tipped blade. If you can’t do that, at least use a steel block plane, drawknife, or other tool to chamfer all eight corners of the board’s ends to remove both surface dirt and the worst of the embedded grit thereby saving your planes, planer and/or jointer blades from scratches.

This step is critical because grit and even small stones frequently become so deeply embedded in endgrain that even a steel brush can’t dig them out. But sure as God made little green apples, Murphy will place them directly in the path of your plane blade.

If you do these things, I promise your tools will thank you over many years with abundant chips, shiny shavings and cheerful little songs.

Well, until either Woody sobers up or we meet again, I have the honor to remain,

YMHOS

Yosemite Valley California, 1865

If you have questions or would like to learn more about our tools, please click the “Pricelist” link here or at the top of the page and use the “Contact Us” form located immediately below.

Please share your insights and comments with all Gentle Readers using the form located further below labeled “Leave a Reply.” We aren’t evil Google, fascist facebook, thuggish Twitter, nor a US Senator’s Communist Chinese girlfriend and so won’t sell, share, or profitably “misplace” your information. May Murphy poke me with his pointy purple pecker if I lie (say that ten times fast!) (ツ).

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Japanese Saws: The Dozuki Saw

Christ in the House of His Parents by John Everett Millais

It is the accuracy and detail inherent in crafted goods that endows them with lasting value. It is the time and attention paid by the carpenter, the seamstress and the tailor that makes this detail possible.

Tim Jackson

This post is about a variety of handsaw unique to Japan called the “Dozuki Nokogiri.”

Description

The name of this saw is pronounced doh/zoo/kee – noh/koh/gee/ri and is written 胴付鋸 in Chinese characters. The first character means “trunk.” or “torso.” The second character means to “attach” something. The third character means “saw.” It’s a thin-bladed, fine-toothed, single-edged crosscut saw with a steel back specialized for making precise, shallow cuts in wood, especially tenon shoulders. Dozuki are not intended for ripping tenons or cutting dovetails, although they can do both fairly well.

Along with the Hozohiki saw, this is the thinnest and most precise variety of Japanese saws, and some, including your humble servant, would say it is the most precise type of saw made anywhere in the world. Certainly, it is the most difficult to make properly.

The Dozuki was the first Japanese saw that became well-known outside of Japan. As many thousands of woodworkers around the world can attest, if you need to make clean, precise, shallow crosscuts, then the Dozuki is a must-have tool.

A variant of the Dozuki is the “Handozuki” meaning “half dozuki.” Handozuki do not have a back steel, but have a slightly thicker and stiffer blade than a normal dozuki, but even then, they are flimsy and more difficult to use than a standard Dozuki. The lack of a back steel, however, allows them to make very precise crosscuts in material where the back steel of a standard dozuki would get in the way. Handozuki were once common, but are seldom seen nowadays.

I have previously written about another variety of Japanese saw with a back steel called the “hozohiki” or “tenon cutter saw.” This type of saw is nearly identical to a Dozuki, although sometimes the blade is shaped slightly different. In any case, it always has rip teeth and excels at cutting precision joints with the grain.

If the Dozuki has a shortcoming, it is the delicate nature of their teeth, which can break when cutting harder woods in a ham-handed manner. Bigger teeth have a larger cross section of steel and are more resistant to breaking than smaller teeth, so it is wise to match the thickness of the Dozuki’s plate and size of its teeth to the hardness of the wood and the user’s sawing skills. In this regard, Western saws with their thicker plates and relatively blunter teeth are much tougher, and in many cases, better suited to cutting harder woods. It’s too bad their precision is often poor.

Using the Dozuki Saw

The proper technique for using a dozuki is to mark the cut with a sharp marking knife and to cut to the line. Goes without saying, right? Perhaps not, because many woodworking gurus in the West advocate first making sawcuts offset from the layout lines and then paring to the layout line using a chisel or a shoulder plane.

While such obviously inefficient techniques may be necessary when using Western backsaws with their thick plates, dull teeth, and excessive set, they are seen by Japanese woodworkers, accustomed to using Dozuki saws, as slow and amateurish.

I strongly encourage Gentle Readers to tune and sharpen their saws and train themselves to cut precisely to the layout line first time, every time.

There are easily-made, simple wooden guides one can use to make this process quicker, but the ultimate guide is a good saw combined with eyes and hands working together confidently. Perhaps I can address the subject of cutting guides and jigs in another article.

As your humble servant mentioned above, the tiny teeth of Dozuki saws are fragile and do not endure ham-handed abuse well. It is recommended that Gentle readers new to the Dozuki saw become accustomed to using it in soft woods such as White Pine before attempting to make a piano from ebony.

Sawteeth are too often damaged by inadvertently banging them against hard objects like a chisel, another saw, or a concrete floor. Please be careful.

Other common causes of damaged sawteeth are forcing the saw too hard, a brutish habit the gods of handsaws frown upon mightily, or swinging the saw left and right in the cut causing the small teeth to snag on the entrance and exit to the kerf, bending and even breaking them. This last cause of damage is perhaps understandable but still about as intelligent as eating boogers. If you are afflicted with any of these unfortunate habits (especially gnoshing on “nose ‘taters”), please make a conscious effort to train them out of your life.

The first bad habit of using excessive force can be easily remedied by simply not pressing down on the saw. Back saws, including both the Dozuki and Western varieties have a steel back that applies downward pressure automatically. You cannot improve on this, so don’t even try.

Using the proper grip can help too. A good rule when using a Dozuki or Hozohiki saws to make precise cuts is to extend the pinkie finger so it is not touching the handle. This makes it much easier to control the downward force your hand puts into the saw. Don’t worry, this grip will not make anyone mistake you for a lady of refinement, unless you are wearing a pretty pink woodworking apron with frilly lace, that is. (ツ)

I like to extend my index finger along the top of the handle because I find this helps me feel the direction of the cut. Your mileage will not vary.

I also like to pinch the saw lightly between the first knuckle of my middle finger and the pad of the thumb forming a single pivot point which helps to keep the saw in proper alignment.

While perhaps a tad anthropomorphic, understanding the following three points about handsaw psychology is absolutely helpful when making precise cuts with any handsaw, or at least that’s what my saws tell me:

  1. A saw cuts because it is sharp and wants to cut (not because you are strong or clever);
  2. A saw cuts well because it is true and sharp (not because you are strong or clever);
  3. Get out if it’s way (because you’re neither as strong nor as clever as you imagine).

The first point is a simple acknowledgment of the nature of the saw, it’s motivations, and your relationship with it. Perfection is unattainable.

The second point is an essential truth of the saw, one many people never understand. Most problems with handsaws can be resolved by truing the plate (an extremely common problem among neglected and/or abused handsaws) and sharpening the teeth. If you fail in this basic duty, your saw will neither be happy nor will it serve you well. Would that humans were as easy to fix.

It all comes together in the third point because, once we understand the nature and truth of the handsaw, and have dutifully made it’s bright blade true and its vicious little teeth sharp, then we must forget how strong and clever we are, get out of its way, and let our skinny buddy do its job.

And just how do we get out of a saw’s way? I just knew you were going to ask:

  1. Keep the saw moving in the right direction. Not as easy as it sounds. But remember, a well-made handsaw is a simple-minded beastie that wants to move in a straight line, so if it doesn’t, it’s your fault;
  2. Rely on the weight of the blade and its back alone to apply adequate pressure (not thy mighty arm, Oh God of Thunder);
  3. Keep your wrist loose and actively rotate it (this is important) so the sawblade moves to and fro only, not side to side. If you lock your wrist, the blade will unavoidably swing right and left and up and down in the cut, hindering the faithful saw, and buggering the precision of the cut it wants to make. This technique requires practice to learn. Do it.
  4. Focus on the sawkerf; Encourage your sharp little buddy to cut true. Banish all distractions, including that bench cat swanning around demanding its lazy servant (that’s you) provide it savory snacks. Using a Dozuki saw is a meditative process. Indeed, an occasional prayer to the gods of handsaws can never go amiss.

The C&S Dozuki Saw

We have a special Dozuki hand-made to meet the severe demands of our professional Beloved Customers. Like our Hozohiki saws, it too is hand-forged from Hitachi Metal’s Yasuki Shirogami No.2 high-carbon steel by Nakaya Takijiro, an extremely skilled craftsman, and one the very few traditional sawsmiths left in Japan. Takijiro hand-scrapes the plate to the proper double-taper to prevent binding, hammer tensions the blade to stiffen it and to prevent it from warping and binding as it heats up in-use, and hand-cuts, hand-files and hammer-sets the teeth.

Very few saws are still being produced to this level of quality and with these performance characteristics. If you need a professional-grade high-precision saw that prioritizes performance over appearance, one that will not get in your way but will help you do better work, then these will be available in limited quantities for a limited time. Unlike me and thee, Takijiro is not getting younger everyday.

You can view our latest pricelist at this LINK.

YMHOS

https://upload.wikimedia.org/wikipedia/commons/2/25/Georges_de_La_Tour._St._Joseph%2C_the_Carpenter.JPG
Joseph the Carpenter by Georges de La Tour

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If you have questions or would like to learn more about our tools, please use the “Contact Us” form located immediately below. Please share your insights and comments with everyone in the form located further below labeled “Leave a Reply.” We aren’t evil Google, incompetent facebook, or twitchy twitter and so won’t sell, share, or profitably “misplace” your information. My arm is untwistable.

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