In this two day class you will make your own custom, 18th century panel saw, based on the Kenyon saw company’s designs. Using fine wood for the handles, brass nuts, and spring steel for the saw plate, you’ll have a finer saw than can be purchased in any store. Master tool maker, Tom Calisto, will work closely with you through the process of shaping the handle, fitting the saw plate to the handle, boring holes for brass nuts, punching the teeth with his retoother, and finally shaping and sharpening the saw to perfection.

About the Instructor:

Tom Calisto is an expert hand tool maker and engineer, with specialty in making historical hand saws. He has been featured on the the PBS TV show “The Woodwright’s Shop“. He also teaches woodworking classes at Roy Underhill’s “Woodwright’s School” and is a regular contributor to Fine Woodworking Magazine and Popular Woodworking Magazine.

Class Syllabus:

DAY 1:

• Clean up handle blank and mark for the hand saw plate
• Cut slot and mortise for the saw plate
• Bore stepped holes through handle for the traditional flush saw nut
• Begin shaping handle to suit students hand for a custom fit

DAY 2:

• Tooth the saw plate using a vintage Foley Belsaw retoother
• Set and Sharpen saw plate
• Punch saw plate for saw nuts
• Assemble saw and tune as necessary
• Polish/finish metal and wood components

Materials Fee:

A class material fee of $60 covers the panel saw making kit, and is payable to the instructor before or on the day of the class. Some students are able to make a second saw within the two days, so any additional saw materials can be purchased from the instructor during the class. Kit prices may vary.

How to Get Here & Where to Stay:

The address of the school is 5700 Buffalo River Rd. Earlysville, Virginia 22936 (Google Maps here). The school is convenient to quite a few hotels, stores, and restaurants, and is only 8 minutes from the Charlottesville airport. Many more details are listed on the school’s main page here.

Class Policies, Liability Waiver, & Cancellations:

A PDF document with the full class policies and a liability waiver will be sent in the order confirmation email. All students are required to sign and return this document prior to attending the class. Anyone can cancel a class up to 2 weeks prior to the class for a full refund (minus a $25 fee that covers credit card processing fees and administrative work). Cancellations under two weeks before a class begins will be given a refund (less $25) if we can find someone else to fill the slot. If we have to cancel a class for an unforeseen emergency, inclement weather, or low number of registrations, a full refund will be given to students.