Now I have always liked compact pack saws, and recently I saw a video of Ray Mears using a very useful looking bow saw.
A quick look showed the nice wooden ones to be beyond my price range while the metal ones felt too flimsy.
While browsing the second hand shop I came across two brand new Sandvik saw blades, one dead wood blade and one greenwood blade, both for only $5.
So once home, a suitable piece of seasoned Kanuka (Tea Tree) was found in my stack.
On the bench planer a flat was planed, then a 90* angle.
I was then able to rip it down on the table saw to 30mm x 30mm (just over 1" x 1")
Once cut to rough length I had a mockup and figured out my measurements.
The female of the tenon was marked out and cut with a 12mm (1/2") chisel.
I drilled the bolt holes on the drill press and then cut the slots for the blade with a handsaw.
I was then able to work out the dimensions of the male tenon and make some cuts initially with the handsaw then a chisel was used to remove the excess wood:
A nice tidy join that is hand tight:
All fitted together it's looking really good if a little bulky, luckily the next step fixes that:
Using a round edge piece in the router all the edges were given a nice edge comfortable in the hand.
A string was tied around it and a rough piece of scrap wood used to tension it up for a test run:
Next I'll round the edges here..........
............make a tight steel ring to prevent any splitting from excessive tension and any jarring forces here.................
............make a tidier more secure tensioner and fit some decent cord, such as paracord...................
............and carve in a groove to hold the cord in place.
First up two pieces of pipe were cut to 15mm (about 3/4") for the metal rings:
The end pieces were trimmed down and the rings were hammered on, the retaining nuts were then welded to the rings so theres no chance of loosing them:
A cord notch was cut in each end piece.......................
..............and a piece of 550 paracord (courtesy of my mate Kiwibowhunter) was fitted.
This cord is strong enough to take all I can give and really allowed me to wind the tension on until a flick of the blade would make a humming sound:
The edges of the strut were finished up:
The tensioner was given a clean up:
Finally all the wood parts were coated with linseed oil and the blades were treated with some WD-40.
A look outside showed a break in the weather so I jumped onto the quad and headed up to the hut to test it out.
Now as you can see it did a fine job of the cut, there was no binding and very little flex in the blade showing I have the tension about right.
The wood I cut was a piece of Kanuka as well.
Finally, a few pics of it with my axe (since re-fitted with a kanuka handle, but thats a story for another time), both assembled and broken down.