Disston 41 Inch 1 Man Crosscut Saw Restore and Horse Packing Case Build

[Blacksmith]

The four bulges in the pic are grommet bosses. Complete thickness of the case is 3/4 inch. Anyone know where you can get grommets that will accommodate 3/4 inch?
I'm going to put a fifth grommet at the toe end of the case also.
The top half of the case will be glued on today.

Looks Like you need the #8 size grommets 0.382" maximum material thickness. McMaster Carr sells them:
http://www.mcmaster.com/#two-piece-grommets/=r91xz1

In either brass PN 9606K49 or nickle PN 87995K59.

You might get away with a smaller size by counter boring the holes to reduce the thickness.

[Just Duke]

Flush route to profile.

[Just Duke]

Sanded and awaiting 5 grommets, Copper Burrs along the edges, 2 Clevis Pins and clips to hold the saw in place and lacquer.


Shown here also is 5 through indexing holes to drill for grommets.

[Just Duke]

Looks Like you need the #8 size grommets 0.382" maximum material thickness. McMaster Carr sells them:
http://www.mcmaster.com/#two-piece-grommets/=r91xz1

In either brass PN 9606K49 or nickle PN 87995K59.

You might get away with a smaller size by counter boring the holes to reduce the thickness.

Thanks for the link Blackie. Is that the largest diameter hole they have?

[Just Duke]

I also need to find some 1 inch Maple to make a couple extra handles.
I hope I live long enough to use all my junk........

[StrawHat]

Look for 5/4 stock at the lumber yard. Or 6/4 stock. Easiest would be to purchase 1x and glue it up. Then machine it down to 1"(5/4). Many of the Disston and other companies saws used apple for the handles. Hard, dense and tight grained with small pores. Easily carved and held details. Much better than maple but a lot harder to find.

[Blacksmith]

Thanks for the link Blackie. Is that the largest diameter hole they have?

I don't know . I knew McMaster carried grommets and those seem to be the biggest they carry. A quick look with Google shows grommet numbers as high as at least #20 but most are made for fabric so the material thickness becomes an issue. A detailed search may find what you want. If you cant find them and you wanted big ones you could probably make some by Metal Spinning.
http://www.instructables.com/id/Meta...-a-Wood-Lathe/

[Just Duke]

I have more scrap 1/4" Baltic Birch and more saws to do. Stay tuned guys.

[Just Duke]

Uh I'm out of White Vinegar....................

[onceabull]

This story motivated me to go out and search for my 3 ft.Bucksaw ,last used around '88 on our last adventure in the Selway country...it's so wet there one needs to cut standing dead ones for wood..or find a place where all the windfall has left some up off the ground.. Onceabull

[Blacksmith]

I ought to go look for mine I have a one man similar to Duke's and blades for two man both softwood and hardwood style teeth.

[Just Duke]

That's great to her guys.
We deneutralized the handle with White Vinegar and it's drying as we speak.

[Just Duke]

This story motivated me to go out and search for my 3 ft.Bucksaw ,last used around '88 on our last adventure in the Selway country...it's so wet there one needs to cut standing dead ones for wood..or find a place where all the windfall has left some up off the ground.. Onceabull

Bitterroot area?

[onceabull]

Yes,(the last two times )going in from Lost Horse Pass... Onceabull

[Just Duke]

Yes,(the last two times )going in from Lost Horse Pass... Onceabull

Ah Nice! I believe Kit Carson ventured through there once or twice. A big man for only being 5'2".

[waksupi]

Yes,(the last two times )going in from Lost Horse Pass... Onceabull

Did you stop at the saloon? The pictures in there of a guy taking his pack string through the saloon is an old friend of mine.

[Just Duke]

Did you stop at the saloon? The pictures in there of a guy taking his pack string through the saloon is an old friend of mine.

Puchi Gap?

[lmcollins]

I fixed up my chipped and split saw handles with accraclass gel. Filed and sanded it to final form. I don't think that bondo would last. It just sort of powders when impacted. For finish I just used Watco Danish Oil. Cheap and easy. Wipe it on thick. Sand it in with a bit of old 400 or 600 grit wet-or-dry paper. Let it soak a while, and wipe it off with a paper towel. Next day give everthing another couple coates. Just soak it up, and then wipe after 10 minutes or so.

For grommets I was wondering if you coulden't make something up out of copper plumbing tubeing. Cut it long and swage one end out with a tapered drift. Put it through the hole in your wood, and then swage out the other end. You are working with wood, and just need to line your holes for tying, and lashing. Maybe swage the tubeing out over a washer. Just thinking to myself. How about plastic pipe? Even easier... maybe with a heat gun.

Good luck. I am just brain storming. You just need easy and cheap. Someone else pickup on my thoughts.

[skeettx]

For your grommets, looks like you may need to use a 444 Marlin case with the head removed,
inserted into the leather and curl both ends
Mike

question: you want grommets for the hollow center for hanging and not rivets just to hold the
leather together, right?

This is a cool place

http://www.brasscomponentsfasteners.com/index.htm

[Frank46]

DUKE, not to get off this thread, but lowes sells a saw made by Corona. Works on the pull stroke is slightly curved and has a wood handle. I keep one on my tractor and it will cut up to 8" logs. Dead wood or green wood sails right through the stuff. Has the teeth similar to the expensive japanese pull saws. Might be worth looking into if you are hurting for space on the pack horse. Frank