DIY Ultimate Ultralight Saw

A reader (Paul – thank you) has gazumped me in the ultralight saw stakes after viewing my post Ultralight Saw Experiments with a ‘saw’ that probably weighs under 5 grams but could still be used to make Ultralight Tent Poles – or similar items of camp furniture.

In his own words (and picture):

“I have some T/U combo blades with a hole. So I just bring a blade and 2 small wood screws, and use a found twig as a handle. I use a SAK screwdriver to install the screws in the handle…it’s a very light and small setup that takes almost no space in my Altoids tin kit.

Here’s a pic of the small saw. IIRC the screws are 3/8″ #4 Phillips head wood screws and I sealed them in about 1cm of drinking straws. One screw goes through the blade hole and the other uses the U notch at the end, to prevent wiggling. The blade when stored is taped inside the Altoids tin lid. The handle is just a 10cm twig I found on the ground.”

And no, I can’t ‘improve’ on this.

PS: Apparently Paul’s saw experiment began with a thread in Bushcraft USA (started by ‘Spork’) a site you might want to check out. Here is his first version of the saw.

However, last week we hiked out to Mt Feathertop and when we arrived at Federation Hut (which otherwise has an excellent pot belly stove) we found that Parks Vic had locked up the bow saw. Nice of them. So no wood for a fire (though we managed to have one anyway – thanks Brett).

You could carry a Fiskars saw with you to cut firewood, as I have previously recommended eg Ultralight Saws but this would weigh 120 grams.

I devised a one-ounce saw which may be difficult for those poor benighted folks who don’t own a (cordless) angle grinder to make (See How to Carry a Saw)

which is why I devised the simpler version in the Ultralight Saw Experiments post, ie the

Ultralight Pruning Saw:

Here I have utilised a piece of 16 x 12 x 1.6mm aluminium channel as the handle – which fits perfectly this type of (demo) saw blade.

The other side.

With the handle trimmed a bit – a one ounce pruning saw.

And folded to fit in the peg bag. It is exactly 6″ (15cm) folded. I can improve on this making a robust handle which weighs less than an ounce ie approx 25 grams.

NB: A saw blade can easily and safely be carried inside plastic Report Cover Spine available for <$1.

Another idea can be found in the Improvised Bow Saw post

An ultralight firewood saw is such an important piece of kit that I invite people to forward me their suggestions.

Here are some ready-made ones:

Reciprocating Saw Handles:

Bosch: 97 grams without the blade – 111 with. Holds two blades inside: “Robust, ergonomically shaped saw handle with a wood sabre saw blade. Top performance for renovations, extensions or working in the garden. Can be used with saw blades for various materials, such as wood, metal and plastic. With storage space in the handle for two saw blades. Universal shank allows the use of the saw blades on both manual and power saws. Replacement saw blades are available at most specialised and general hardware stores”. US$23.05 (May 2024) You can use a Report Cover Spine to hold spare/longer eg pruning saw blades.

Here is another one: https://www.bunnings.com.au/toughbuilt-folding-jab-saw-4-blades_p0585833 A$49.98

And another https://www.amazon.com/Drywall-Lockback-Klein-Tools-31737/dp/B07DKRCNX3?th=1

And another: https://www.bunnings.com.au/kango-152mm-all-purpose-folder-jab-saw_p6350894 A$ 29.98 207 grams

PS: I bought the Kanga this morning and disassembled it to see if I could lighten it (possibly) and to see what makes it ‘tick’. Though I can’t reuse the mechanism it did give me an idea for a more robust handle (than my prototype above) made out of three pieces of aluminium flat bar – or perhaps two pieces of aluminum and parts of a saw blade (or steel) for the centre section – plus probably a bolt or one of those two-part screws which screw into each other to hold it all together. I estimate this handle should not weigh any more than an ounce yet should create a saw robust enough to cut firewood (with the appropriate saw blade/s.)

You also must have a knife