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Old 06-17-2010, 11:40 PM
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Default Bad Axe Beastmaster & Roubo Dovetail

Lady & Gents,

A few weeks back Mark Harrell from Bad Axe sent me a prototype of his Beastmaster saw to try out. The Beastmaster absolutely lives up to its name. The saw blade is 18 inches long, the plate is .032 thick and you have just over five inches under the hardback. In addition the saw weighs in at 2 lbs 4.5 ounces. If you are looking for a real upper body workout just take this saw out and start making some five inch deep cuts. It may be different with you all but I had major lactic acid buildup in my upper arm and shoulder.

Mark had asked if I would in particular make the cuts as if I was building the Roubo bench with the huge dovetail and tenon at the top of the bench legs that are five inches by five inches. As I am not yet ready to build that bench I did an 18 inch long glue up of five inch by five inch white oak.

So, the first thing I did was notch the four corners of the white oak and used the Beastmaster to square off the top. I actually had to do this twice as the first time I stopped turning the wood and went through with a part that was quite a bit higher than the rest. I re-notched and this time kept turning the oak as I was sawing and ended up with a much better looking top. I still had to touch up the top with a plane but that was not an issue with the saw but an issue with the sawyer.

The next thing I did was draw out the layout lines for my saw lines. In order to make this work you need to make three straight cuts five inches down. The first two cuts are the ones that define the space between the dovetail and the tenon. The cuts are one and a half inches apart. The third straight cut is on the back of the tenon and is a half of in inch from the back and also five inches down. After the cut behind the tenon I took my Lie-Nielsen carcass saw and made a half inch deep crosscut at the bottom of the third cut. After making that cut I now had a half inch shoulder behind the tenon. I then turned my attention to the inch and a half gap between the first and second cuts. The entire five inch deep inch and a half across piece had to come out. Normally or a normal person would have first drilled out that section or made as many five inch deep cuts in between that you can. But NOOOOOOO.

I picked up two of my very heavy duty mortise chisels from Harold & Saxon, one which is a half inch wide and the other which is a one inch wide. In addition I brought my wooden Pfeil mallet and my green acrylic infused mallet from Blue Spruce. I then beat the crap out of both mallets and you will be able to see the differences in the picture. Very, very cathartic.

After that was done, I made the two 45 degree five inch deep cuts to define the dovetail and then it was finished. I have a lot of pictures and I am going to post them in several posts. I hope that you all will enjoy.

Fred






































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Old 06-17-2010, 11:52 PM
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Kapex, OF2200,Domino,TS 75, Trion PS 300, RO 150, RO 90, ETS 150/5, ETS 150/3, DTS 400, RS 400, LS 130, RS 2, Deltex 93, RAS 115, CT 33, CT 22, CT 26 CT Midi, OF 1400, MFK 700, C 12, LR 32 3, Shinex, MFT/3s, 3 MFT 1080s, WCR 1000, UG-KA-SET, 10 Sysports, 2 Walko's, Marcou's J20A, S20A, M12, S45, S55A, VSP 40, Brese 650-55J, Sauer & Steiner XSNo.4, SS Jointer, A5 Desert Ironwood and #4 Damascus, Knew Concepts 8 inch Fretsaw, Knew Concepts 5 inch Titanium Fretsaw, Hammer K3 48x48, Hammer A3 31
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Old 06-18-2010, 12:09 AM
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Old 06-18-2010, 12:36 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail Page 3

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Old 06-18-2010, 03:30 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail

Fred, no offence, but a chain saw would have produced the same results...

Love Mirko.
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Old 06-18-2010, 03:42 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail



I torn between laughing and sympathy because I couldn't do any better.

I went with laughing...
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I don't have as many Festools as Fred. Or Marcou's, or Brese's, or Lie-Nielsen's, or Lee Valley's, or Blue Spruce's, or Harold and Saxon's, or...
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Old 06-18-2010, 04:17 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail

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Originally Posted by Mirko View Post
Fred, no offence, but a chain saw would have produced the same results...

Love Mirko.
The Dude couldn't have said it any better.
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Old 06-18-2010, 10:47 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail

Great pictures Fred! You certainly can see the difference in quality of the two mallets. The Blue Spruce wins hands down. Was all of that wear on the Pfeil mallet just from this one session?!?
It still amazes me that those Harold & Saxon chisels intended for very heavy duty use weren't socket chisels???
Very nice expose' on the Roubo leg joints Fred, Thanks!
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Old 06-18-2010, 11:19 AM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail

Always liked that Blue Spruce mallet, but wondered how durable it was. This looks like I could even beat my head with it and it would survive. I'll move it up on the list of things to get
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Old 06-18-2010, 04:30 PM
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Default Re: Bad Axe Beastmaster & Roubo Dovetail

Quote:
Originally Posted by Mirko View Post
Fred, no offence, but a chain saw would have produced the same results...

Love Mirko.
Mirko,

No offense taken whatsoever. The reality is that I am not that good with a chainsaw and to me it would not have been nearly as much fun.

Fred
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