Coping Saw

In this project, you'll find out how hardwood and aluminum combine to make a lightweight saw that’s tough enough for all kinds of tasks.

Mention “shop-built hand tools” and a few images likely spring to mind. Maybe it’s a wood hand plane a la James Krenov, or wood layout tools, or even a simple shop knife. Creative Director Chris Fitch aims for this coping saw to expand the concept into something a little more complex. At the same time, the project should be as accessible as possible to woodworkers. Metalworking can be a stumbling block for toolmaking. Chris’ solution is to use a highstrength aluminum alloy. This means that the hardware components you see in the photo can be made easily with tools you probably already have in your shop. Another benefit to the aluminum is its light weight. That made it ideal for the frame. Coping saws tend to be underappreciated, even by hand-tool woodworkers. And frankly, most commercial versions are average at best. I’ve found that a coping saw is an ideal sidekick to your other hand saws for creating curves or cutouts that other saws can’t handle. A well-made, top-performing tool invites you to use it more often. So it’s time to build.

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What You Get:

  • 8 pages of step-by-step instructions
  • 30 full-color photos, illustrations, and exploded views
  • Materials List & Project Supplies Sources

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