How to Make a Folding Bow Saw: Step-by-Step DIY Guide
Building your own folding bow saw is not just a satisfying project, it also gives you a lightweight, portable tool that works well in the outdoors. Whether you’re planning a camping trip, need a backup saw for your toolbox, or enjoy making your own gear, a folding bow saw can be both practical and fun.
Many commercial folding saws cost more than $30 and sometimes break under tough use. Making your own lets you choose better materials, customize the size, and understand the tool’s mechanics. Even if you’re new to woodworking, this guide breaks down the process with simple steps, tips, and clear explanations to help you succeed.
What Is A Folding Bow Saw?
A folding bow saw is a type of hand saw designed for easy transport and storage. Unlike a regular bow saw, its frame folds down, protecting the blade and saving space. You’ll often see people using these saws to cut firewood, branches, or small logs when camping or hiking. The folding feature means you don’t need a separate blade guard and can safely keep it in your backpack or toolbox. Most folding bow saws use a replaceable blade held under tension by the frame, just like a classic bow saw.
Why Build Your Own Folding Bow Saw?
Buying a folding bow saw is easy, but building your own has several advantages:
- Customization: Choose the length and materials that suit your needs.
- Durability: Select stronger woods or metals than many budget saws.
- Cost: Save money, especially if you have leftover materials.
- Learning: Gain woodworking skills and confidence in toolmaking.
In my experience, homemade folding saws often last longer and feel sturdier than cheap store models. Plus, they’re a great conversation starter at any campsite.
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Tools And Materials You’ll Need
Before starting, gather the following tools and materials. The specific sizes can be adjusted based on your needs, but these recommendations work well for a mid-size (18-21 inch blade) folding bow saw.
Essential Materials
- Saw blade: 18, 21 inch bow saw blade (available at most hardware stores)
- Hardwood: Two pieces for the arms (each about 1 inch x 1.5 inches x 17 inches)
- Hardwood crossbar: One piece (about 1 inch x 1 inch x 12 inches)
- Pivot bolts: Two 1/4 inch diameter, 2-inch long bolts with matching wing nuts
- Tensioning bolt or paracord: For holding the frame tight
- Brass or steel pins: For blade attachment (about 1/8 inch diameter)
- Washers: To reduce friction at moving joints
- Epoxy or wood glue: For optional reinforcement
- Finish: Tung oil or polyurethane for weather protection
Required Tools
- Hand saw or miter saw: For cutting wood to length
- Drill and drill bits: For making holes for bolts and pins
- Chisel: For notching the frame, if needed
- Screwdriver and wrenches: For tightening bolts
- Sandpaper (120 and 220 grit): For smoothing edges
- Measuring tape and pencil: For marking cuts
- Clamps: To hold pieces in place during assembly
Optional Tools
- Router: For rounding edges
- File: For smoothing metal parts
- Wood rasp: For shaping handles
Pro Tip: If you want a lighter saw, consider using aluminum for the crossbar instead of wood. It saves weight and resists moisture.
Planning The Folding Bow Saw Design
The classic folding bow saw design uses two side arms, a crossbar (stretcher), and a blade. The arms pivot at one end to fold flat against the crossbar and blade. When unfolded, the arms and crossbar form a rigid triangle, holding the blade tight.
Frame Dimensions
The most common blade sizes are 18, 21, and 24 inches. Choose a size based on your needs:
| Blade Length | Ideal Use | Frame Size (Arms) | Weight (approx.) |
|---|---|---|---|
| 18 inches | Backpacking, light use | 17 inches | 1.1 lbs |
| 21 inches | General camp use | 20 inches | 1.3 lbs |
| 24 inches | Heavy-duty, car camping | 23 inches | 1.6 lbs |
Most people prefer the 21-inch blade for a balance of weight and cutting ability.
Folding Mechanism Options
There are two common folding systems:
- Pivoted arms: The arms rotate on bolts at the crossbar ends, letting them fold flat.
- Detachable crossbar: The crossbar can be removed so the arms and blade nest together.
Each has pros and cons. Pivoted arms are faster to set up, while a detachable crossbar lets you pack the saw even smaller.
Blade Attachment Styles
- Pinned: Small steel or brass pins hold the blade to the arms.
- Slotted: Blade ends fit into slots in the arms, secured by bolts.
Pinned attachment is stronger for heavy cutting. Slotted is easier for beginners but may not hold as tightly.
Step-by-step Guide: Making Your Folding Bow Saw
Follow these steps to build a reliable, folding bow saw suited to your needs.
1. Cut And Prepare The Frame Pieces
Start by cutting your hardwood to the correct lengths:
- Arms: Two pieces, each 1 inch x 1.5 inches x blade length minus 1 inch.
- Crossbar: One piece, 1 inch x 1 inch x blade length minus 6-8 inches.
Sand all surfaces smooth, paying extra attention to the handles. A smooth handle reduces blisters and feels better during long use.
Pro Tip: Slightly round the arm edges with sandpaper or a router for improved comfort and style.
2. Drill Pivot And Blade Holes
Mark and drill holes for the pivot bolts at one end of each arm (about 1 inch from the end). These holes should match the diameter of your bolts.
At the opposite end of each arm, drill holes for the blade pins or bolts. The distance between these holes must match the length of your saw blade. Measure carefully, too far apart, and the blade won’t fit; too close, and it will be slack.
If your saw uses a tensioning cord, drill a hole through the upper part of each arm (about 1 inch from the top) for the cord to pass through.
3. Assemble The Frame
Attach the crossbar between the arms using your pivot bolts and wing nuts. Test the fit, when unfolded, the arms should form a wide “U” shape with the crossbar at the base. When folded, the arms should lay flat against the crossbar.
If you’re using a detachable crossbar, fit it with dowels or tenons that slot into matching holes in the arms.
4. Attach The Saw Blade
Secure the blade to the arms using brass or steel pins, or bolts if your blade has holes for them. Make sure the blade teeth face outward and downward.
The blade should be snug but not forced. If it’s loose, add washers or bushings to the pins to take up the slack.
5. Add The Tensioning System
A folding bow saw needs tension to cut well. There are two common systems:
- Tensioning bolt: A threaded rod runs between the tops of the arms. Tightening a wing nut pulls the arms together, making the blade tight.
- Paracord and stick: A strong cord is tied between the tops of the arms. A small stick is twisted in the middle of the cord to wind it up, pulling the arms together.
The paracord system is lighter and works well for most people. The tensioning bolt is easier to adjust, especially in cold weather.
6. Test And Fine-tune
Unfold your saw, tension the blade, and test it on a branch. The frame should feel solid, with no wobble, and the blade should not flex sideways. If you notice any looseness, check the bolts and pins, and retighten as needed.
If the saw feels uncomfortable, sand the handles more or add grip tape.
7. Apply Finish
Wipe down all wood parts, then apply tung oil or polyurethane to protect against moisture. Let it dry thoroughly before use.
Example: I once skipped this step on my first homemade saw, and the frame swelled after one rainy day in the woods. Now, I always finish my tools before taking them outdoors.
Folding Bow Saw Design Variations
You can customize your folding bow saw in several ways, depending on your needs and available materials.
Handle Shapes And Grips
Some people like straight handles, while others prefer curved or contoured grips for comfort. You can wrap the handles with paracord or rubber tape for extra grip, especially in wet weather.
Frame Material Alternatives
While hardwood is traditional, aluminum or carbon fiber can reduce weight. However, these require more advanced tools and skills to shape and drill.
Blade Types
You can use a standard bow saw blade or a specialized blade for dry or green wood. Some blades have extra-hardened teeth for cutting frozen wood or dense tropical species.
Collapsible Crossbar
A two-piece crossbar connected with a threaded insert packs even smaller. Just be aware that this may reduce the frame’s strength.
| Design Feature | Benefits | Potential Drawbacks |
|---|---|---|
| Curved Handles | Better comfort, less hand fatigue | Harder to make, bulkier when folded |
| Aluminum Frame | Lighter, rust-resistant | Needs special tools, can bend under heavy use |
| Two-Piece Crossbar | Packs smaller, easier to carry | Less sturdy, more parts to lose |
Credit: paulkirtley.co.uk
Safety Tips For Using And Carrying A Folding Bow Saw
Bow saws are simple tools, but they can cause injuries if used carelessly. Here are some important safety guidelines:
- Always fold and secure the blade when carrying the saw.
- Wear gloves to protect your hands from slips and sharp teeth.
- Cut on stable surfaces and keep fingers clear of the blade path.
- Check the frame and blade for cracks or damage before use.
- Store the saw in a dry place to avoid rust and warping.
Pro Tip: If you hike or camp in areas with strict safety rules, use a blade cover or wrap the folded saw in a cloth to prevent accidental cuts.
Common Problems And How To Fix Them
Even a well-made folding bow saw can have issues. Here are solutions to the most frequent problems:
- Loose blade: Re-tension using the cord or bolt. If that fails, check for worn holes or pins and replace them.
- Frame wobble: Tighten all bolts and check for cracks. Replace damaged parts promptly.
- Blade binding in wood: Use a blade with larger teeth for wet or soft wood. Keep the saw moving steadily, and don’t force the cut.
- Handle discomfort: Sand more or add grip tape until comfortable.
- Stuck folding mechanism: Clean out dirt and apply a little oil to the pivots.
Maintaining Your Folding Bow Saw
A little care goes a long way in keeping your saw in top shape.
Cleaning
After each use, wipe off wood dust and sap. If the blade gets sticky, scrub it with a rag and a few drops of mineral spirits.
Blade Care
Keep the blade dry to prevent rust. If it dulls, replace it, most blades are not worth sharpening by hand.
Frame Upkeep
Check wooden frames for cracks or splinters, and sand or glue as needed. For metal frames, look for bends or loose rivets.
Storage
Store the saw folded, in a dry place. If you’re storing it for a long time, loosen the tension to avoid warping the frame.
Folding Bow Saw Vs. Other Portable Saws
How does a folding bow saw compare with other portable saws? Here’s a quick look:
| Saw Type | Cutting Speed | Pack Size | Ideal Use |
|---|---|---|---|
| Folding Bow Saw | Fast (large teeth) | Medium | Firewood, thick branches |
| Folding Pruning Saw | Moderate (fine teeth) | Small | Small limbs, gardening |
| Wire Saw | Slow | Tiny | Emergency only |
| Chainsaw (manual) | Varies | Small | Large logs, survival |
A folding bow saw offers the best balance between speed, size, and ease of use for most outdoor situations.
Where To Find Quality Saw Blades
The blade is the heart of your bow saw. Use only high-quality, hardened steel blades for best results. Look for blades from established brands at hardware stores or online retailers. If you need more details about saw blade types and uses, the Bow Saw Wikipedia page is a good resource.
Pro Tip: Always carry a spare blade in your pack. Blades can break or dull unexpectedly, and replacements are light and inexpensive.
Frequently Asked Questions
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What Wood Is Best For Making The Frame Of A Folding Bow Saw?
The best woods for a folding bow saw frame are dense hardwoods like hickory, ash, or oak. These woods resist bending and cracking under tension, making your saw
