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Every hand-tool woodworker needs a minimum of three backsaws: Dovetail, Tenon, and Crosscut Saws. I design and manufacture two Tenon Saws to meet this requirement: my Large and Medium Tenon Saws.
My Large Tenon Saw is built for the professional or advanced hobbyist woodworker. Its size and weight provides you the capability to cut even the largest tenons, however; it requires that you have already mastered the skills to control the saw. My Medium Tenon Saw is built for the hobby woodworker and is specifically designed to make learning how to cut tenons easy.
Both of my tenon saws are heavier than most providing you with better saw balance and reduced vibration. The weight, combined with the pistol grip style handle, trains you to make straight, perpendicular cuts. The relaxed cutting angle of the small front teeth starts the cut with ease and the diamond-saw formed teeth slice straight through the wood giving you a ready-to-joint surface.
This saw is designed for the professional or advanced hobbyist woodworker. Its size and weight provides you the capability to cut even the largest tenons, however; it requires that you have already mastered the skills to control the saw. The 20 TPI teeth with a relaxed cutting angle on the first two inches of the blade makes for easy saw starts, 12 TPI teeth on the rest of the saw quickly and efficiently makes precise cuts in the densest hardwoods. 2-3/4" depth of blade allows you to handle very large tenon cuts. and the.025" thick blade; provides the stiffness needed in a large saw.
Product Details:
Size. Overall length (Toe to handle tip): 17 inches. Blade length (Toe to heal): 12 inches. Depth of blade under the back: 2-3/4 inches.
Weight: 22-24 ounces.
Blade: Made from .025 thick, spring steel.
Tooth Geometry: First 2" are filed rip at 22 TPI with a negative 25 degree rake. The remaining teeth are filed rip at 12 teeth per inch (TPI) and a negative 17 degree rake.
Set: Unlike most saw manufacturers who stamp out their saw teeth, leaving "dimples" in the blade, we individually cut out each of our saw teeth with diamond impregnated saws. This allows us to maintain a very slight set of only .002 inch (per side), since we don't introduce that "dimple" onto the blade. This slight set produces a narrow .029 inch kerf that eliminates slop allowing the saw blade to accurately track in the saw kerf resulting in dead straight saw cuts with smooth ready to glue surfaces.
Brass Back: 1/4″ thick x 1″ wide brass back is secured to the blade with peened and flushed copper pins. Not only does the brass look wonderful but it imparts extra weight to the saw, as compared to our competitors saws, that provides you a better balanced saw, allows the saw to do the cutting work, and helps you "feel" perpendicular.
I haven't cut a lot of tenons with this saw yet; I am not in the middle of a project of the appropriate size. But I have cut a number of test tenons in different woods and this saw has handled the task better than any saw have ever used. It takes a bit more practice than, say, the dovetail saw because the starter negative rake teeth are a lot farther from your hand, somewhat harder both to see and control. ( Also my long habit with saws that don't have a negative rake section is to start with a section of saw closer to my hand. ). But still the negative rake teeth are very cooperative in starting a cut. And the handle is excellent at ergonomic feedback, though I was initially unconvinced by its edgy shape. Most of all, this saw seems to cut straighter than others I have used. Not sure why that is, maybe a more precise cut and set so that it doesn't have any sort of "drift" like bandsaw blades sometimes do. It takes quite a bit of work to make a tenon by hand, but a saw that cuts accurately and straight makes the entire process go a lot more smoothly. My wife sews leather sheaths for my most valuable tools, and she likes the looks and feel of this saw. ( If anyone is interested, she uses a Sailrite portable, which can handle fairly thick 4-5 oz leather, and puts a reinforcing leather strip between sheath sides for saw teeth to bed on. )
As always very good quality. Practically have all the different saws. Wouldn’t ever need to buy others.
I only just received the Large Tenon Saw I ordered, so I've only made a few cuts to try it out. I do own one of the Medium Tenon Saws and I can already tell this one is of the same great quality. The real story here is customer service. One word, outstanding!
When I received my large tenon saw, unfortunately it was damaged in shipping. A small chip and crack in the upper horn on the handle. I took a few photos as I was unpacking the saw and sent them along to the service department. Gina responded the next day with a sincere apology, a pre-paid return shipper, and instructions for the return.
Before I had a chance to print the shipper and box up the saw another saw was already on it's way! The saw arrived a week later, in a larger box, and included a small "We're Sorry!" bottle of their maple syrup. The pancakes at breafast the next day taste extra special with a good dose of outstanding customer service on top!
That's how it's done people, truly 110%.
Thanks Gina, Rob, and the team at Rob Cosman Tools.
Rick
This actually arrived while mid project in the garage and it went straight from the delivery guy to me cutting wedged tenons. I have Robs dovetail and the beloved joinery crosscut (best saw on earth) and this tenon starts just as easy and cuts just as nice. The shoulders I’ve used it on so far were pretty thin at only 2mm and maybe 30mm long and this saw was great. It’s obviously heavy (just like it says) but it’s easy to be delicate and I like having the extra depth. Joinery and “window” things in photos were 100% hand cut. Walnut/maple & Osmo
I won a panel saw in the drawing a few weeks ago but decided that was something i wouldn't get much use out of , so asked that if I paid the difference could I switch to the large tenon saw. They kindly obliged. I own three other cosman saws and I must say that this one is even more impressive than the others, and that is saying alot.
