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Bad Axe Tool Works 10" Carcase Saw, $235
(Delivery: 5-7 weeks)

Build Your Saw:
Type Filing
Desired Pitch
Sawback Preference
Open or Closed Handle
Handle Species
Hand Size (how to measure)
Preferred Fasteners
Make Deposit

Luthiers and cabinetmakers will love this saw. Ever make a cut with a vintage Disston No. 4-10? Typically, they were produced in a closed-handle design, but the company also made saws for hardware stores with an open handle, and an etch unique to their companies back in the day. These vintage saws easily pull double-duty as as a dovetail saw, and that is why so many woodwokers snap a quality Disston No. 4-10 off eBay for their dovetailing and carcase cross-cutting requirements. Bad Axe now produces both open and closed-handled versions of of this fine 10" back saw for inclusion in your woodworking arsenal.

Here's a run-down on the specs:

  • Quartersawn hickory, or optional cherry, walnut, or fiddleback maple open handles. Closed handles available on request.
  • Traditional folded gunsmith hot-blued (black-oxided) carbon steel or optional brass, bronze, bright nickel-plated or copper-plated carbon steel sawbacks.
  • Fasteners in standard brass or optional gunsmith-blued or stainless alloys.
  • RC 50-52 .02-thin premium Swedish spring steel sawplate.
  • Filed 14 ppi x-cut, with moderate-to-aggressive rake, and slight fleam & gullet to reduce tearout.
  • Depth of plate under the back runs 2 1/2" across the toothline.

Why do I want this saw? If your crosscutting requirements range often between 1/2" and 6/4" dimensions with the occasional need for deep cuts up to 2.5", then this is a saw you'll want in your till. Just starting out with a very limited budget? Then here's your hybrid dovetail/carcase/small tenon saw until you can afford something for projects requiring more robust dimensions, and it will continue to see primary service as a dedicated crosscut saw for fine work after you've added more saws to your arsenal.

How do I want this puppy filed? Strongly recommend 14 ppi hybrid-cut. You will not go wrong with this filing. If you regularly have a 4/4 to 6/4 tenon cheek ripping requirement, then I'd recommend 14 ppi dedicated rip. Only require a saw for careful, delicate crosscuts in the 1/4 to 1/2 range? Go with 15 ppi x-cut. Want to do both rips and cross-cuts with an eye toward expanding your repertoire in the future? Stick to the hybrid-filing.

dropThe story behind our new shock-resistant handles. About once or twice a month, one of my customers will call in seeking a replacement handle after having accidentally swept their Bad Axe from benchtop to floor. We have now fielded shock-resistant handles in response to that scenario for those who use their tools hard, but don't want to compromise the natural beauty of a solid hardwood handle. Our new laminate handles fuse a top-quality 13-ply hardwood laminate with a genuine hardwood outer sheath. The 3/4" thick, 13-ply laminate is formed in perpendicular layers, resulting in a VERY tough and stable inner core with an attractive edge. We sheath the core with hardwood to enhance visual appeal. As for its durability? Frankly, a resin or plastic handle is tougher--but who wants a synthetic handle? Our laminate handle will dent slightly when dropped horns-first onto a concrete floor from a height of six feet, but that's about it. The horns sure as heck won't snap off, and the body won't check. Click onto my YouTube video on the left to see how this handle reacts to a 6' drop onto my workshop floor, and judge for yourself.
Hand Measurement
Sizing Handles: Here's my hand: it measures about 3 3/4" across. That's what I'm calling regular, and it will work with a range from 3 5/8" and start getting tight at 3 7/8." Bigger hands just under 4" up to 4 1/8" spans will require the size Large handle, and 4 1/4 to 4 3/8 will want an Extra Large. Going the opposite direction, if the span of your hand measures in the 3 ¼ up to 3 1/2" range, then we're looking at a size small handle. Really tiny hands from 2 ¾ up to 3 1/8 should warrant an XS handle.
(return to sizing menu)

 

"Where can I buy my own mesquite--or for that matter, a unique species I'd prefer to supply myself for the handle?"


Finding a reputable lumber dealer can be challenging, particularly when you're looking for a well-figured species that won't let you down. The good people listed below will never steer you wrong--these are companies that Bad Axe has used over the past eight years with consistently reliable results when it comes to sourcing high-quality stock you'll be happy with.

Mesquite Valley Woodcrafts Nave's Sawmill & Woodworks Horizon Wood
(Mesquite & other TX hardwoods) (Mesquite & other TX hardwoods) Any North American Hardwood)

Dimensions Required for shipment of customer-supplied wood to Bad Axe:

  • Length: 8.5" Long with the grain.
  • Width: 6.25" wide.
  • Thickness: can range between 4/4 and 5/4 thick. Do not fall below a full 4/4, given that we mill to a finished thickness of 7/8".
  • Type Cut: Quartersawn stock (mitigates wood movement with seasonal change. Do NOT send flatsawn stock. The only exception to this is mesquite, which has interlocking fibers and naturally resists warping despite type of cut.
  • Condition & Moisture Content: at or about 8% moisture content. No cracks, splits or defects in the blank.
  • Quantity, best to send two blanks, in case the first one has an unseen defect. This very seldom happens, but best to be prepared for it. We will return the unused blank or save it for future milling on your behalf.
  • How to ship: Have the supplier label each wood blank by taping your name & contact information (billing address, cell & email--your purchase receipt will also suffice), and drop-ship your blanks to our workshop at: Bad Axe Tool Works, 1500 Green Bay St., Suite #508, La Crosse, WI 54601. Please alert us when this is put into motion, so we may track your package’s arrival.

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All Bad Axe Tool Works Saws are highly customizable, and Feature the Following:

  • Custom filing available at same price per request
  • Bad Axe saw sharpening rates $15 nominal fee
  • Highly-figured 19th-century patterned hickory handles, also available in cherry, walnut, maple & mesquite.
  • Five handle sizes available: XS, S, R, L, XL
  • Flush-face slotted sawbolts/nuts in three alloys and four finishes with a 13/16" deep-dish decorative medallion
  • Firearms-quality hot-blued finish on traditionally-folded steel back
  • Optional black or bright nickel carbon steel, brass, copper-plated and bronze saw backs
  • Premium-grade Swedish Spring Steel, RC50-52
  • Traditional hammer-set toothline
  • Lifetime guarantee against all material defects

Learn more about my material choices and saw design rationale.

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