In the above video, Tom Calisto shows how to cut perfect new saw teeth using a vintage Foley hand saw retoother machine. Over the years, the Foley Manufacturing Company made several versions of their retoother. Most machines were driven by a motor and some were manually powered. When teaching his hand saw making class in our traditional woodworking school, Tom uses the Foley #332 retoother (which you can see here at Ebay). I use the Foley 385 retoother (which you can see here at Ebay).

I also own two other vintage Foley machines used for sharpening hand saws, including the 387 automatic saw filer (which you can find locally through Facebook Marketplace and Craiglist, or here on eBay) and the Foley 352 power saw tooth setter (find here at eBay, or on Facebook Marketplace and Craigslist…don’t confuse it with the circular saw blade setter).

Keep in mind that these three machines can be used to fully sharpen hand saws, and they all use the same hand saw carrier bars (which holds the saw) and ratchet bars (which give you different sized teeth). But when buying one of the above machines, make sure that you get at least one carrier bar and that you can find ratchet bars somewhere. Because the machines won’t work without either. Most of these vintage Foley machines are missing ratchet bars, so keep your eyes open for them somewhere else.

If you’d like to learn more about Foley hand saw retoothers, keep reading below…

The Origins and Evolution of the Foley Retoother

In the world of saw sharpening, precision and efficiency are paramount. For enthusiasts and professionals alike, tools that streamline the process while maintaining quality are invaluable. One such tool is the Foley Retoother, a machine designed to punch teeth into saw blades, ensuring uniformity and speed. Though not as common today as they once were, the Foley retoother remains a cherished piece of equipment for those who appreciate its craftsmanship and utility. In this article, we’ll explore the function and benefits of the Foley Retoother machines, along with some of its historical context and practical considerations.

The Foley 332 Retoother is part of a larger family of retoother machines, originally manufactured in Minneapolis, Minnisota by the Foley Manufacturing Company, to assist in the repetitive and laborious task of re-punching saw teeth. The Foley-Belsaw Company, which became known for producing a variety of sharpening and saw-related tools, created several models of retoothers over the years, with the Foley 332 being one of the more popular ones. There were other brands and models available, such as those produced by Acme, but Foley machines, including the 332, earned a reputation for durability and precision. You can find different Foley models and user manuals at the Vintage Machinery website, here.

At a time when most saw sharpening was done manually, saw sharpening machines offered a significant leap forward in terms of speed and uniformity. Prior to the availability of such machines, sawyers would spend hours filing each tooth by hand, a painstaking process that required both skill and patience. While hand-filing is an excellent way to develop proficiency in saw sharpening, it is not the most efficient method, especially when large numbers of saws need to be maintained. The Foley retoothers allowed users to quickly and consistently punch teeth into the saw plate, making it an indispensable tool for many saw sharpening shops.

How the Foley Retoother Works

At its core, the Foley Retoother is a relatively simple machine, yet its design allows for precise control over the process of punching teeth into a saw plate. The machine consists of several key components, including the ratchet bar, carrier bar, flywheel, and a punch and die mechanism.

• The Ratchet Bar: Positioned at the top of the machine, the ratchet bar is responsible for moving the saw plate forward incrementally. This ensures that each tooth is spaced evenly from the next, a critical factor in achieving uniform cutting performance.

• The Carrier Bar: The carrier bar is the component that holds and supports the saw plate during the tooth-punching process. It keeps the saw blade in place, ensuring that it is properly aligned with the punch and die.

• The Ratchet Paw: Attached to the machine, the ratchet paw engages with the ratchet bar to move the saw plate forward one step at a time. This is synchronized with the rotation of the flywheel, ensuring that each time the flywheel moves, the saw plate advances the correct distance.

• The Flywheel: The flywheel is the driving force behind the machine. As the motor rotates it, the flywheel powers the punch and die mechanism, which punches the teeth in the saw plate. Each rotation of the flywheel results in the punching of one tooth, and the saw plate is simultaneously advanced by the ratchet paw.

• The Punch and Die: Located inside the machine, the punch and die are the components that physically create the teeth in the saw plate. The punch is a small metal tool that presses into the saw plate, while the die is a matching shape that receives the punch. Together, they form the precise tooth pattern required for effective cutting.

When the machine is started up, the flywheel begins to turn, and the ratchet paw moves the saw plate forward incrementally. With each movement of the flywheel, the punch and die engage, pressing a new tooth into the saw blade. This process continues until the entire saw plate has been toothed, at which point the saw is ready for the next step in the sharpening process (either saw setting or saw filing).

The Benefits of Using a Foley Retoother

There are several key advantages to using a Foley Retoother over hand-filing or other methods of tooth-punching. These benefits make it an attractive option for both professional saw sharpeners and hobbyists who want to maintain high-quality saws with minimal effort.

1. Speed and Efficiency

One of the primary advantages of the retoother is its speed. Compared to hand-filing, the machine can punch teeth into a saw plate in a fraction of the time. This is particularly important for those who need to sharpen multiple saws or maintain a large collection of saws. By automating the tooth-punching process, the retoother allows users to complete their work quickly without sacrificing precision.

2. Uniformity and Consistency

Another significant benefit of the hand saw retoother is the uniformity it provides. When hand-filing saw teeth, it can be challenging to ensure that each tooth is the same size and shape as the others. Even experienced sharpeners can struggle with maintaining perfect consistency, especially over long periods of time. The retoother eliminates this issue by using a punch and die system that ensures each tooth is identical to the next. This uniformity results in a saw blade that cuts more smoothly and efficiently.

3. Ease of Use

Despite its technical appearance, the Foley retoothers are relatively easy to use. Once the saw plate is properly secured in the carrier bar and the machine is set up, the process of punching teeth is straightforward and fast. The operator simply needs to monitor the machine as it runs, ensuring that everything is functioning correctly.

4. Availability of Replacement Parts and Modifications

While none of the Foley machines are in production, it is still possible to find used machines and parts on platforms like eBay, Facebook Marketplace, and Craigslist. However, one thing to be aware of is that many of these machines are sold without essential components like the carrier bars or ratchet bars. Without these parts, the machine is essentially useless. For those who are mechanically inclined, it is possible to fabricate replacement parts. Some users have even made their own ratchet bars, allowing them to customize the machine to suit their needs. Some people make and sell ratchet bars (including Tom Calisto).

The Value of Learning Manual Hand Saw Sharpening First

While the Foley 332 Retoother is a valuable tool for anyone looking to improve their saw sharpening process, it’s worth noting that there is still great value in learning how to sharpen saws by hand. Before acquiring a retoother machine, many saw sharpeners, including Tom Calisto, would manually file each tooth. This method, while time-consuming, teaches valuable skills in precision and attention to detail.

Hand-filing requires a deep understanding of tooth geometry, spacing, and the overall mechanics of saws. For those who are passionate about the craft, the process of hand-sharpening can be meditative and rewarding. It also provides an intimate understanding of how saws work, which can be invaluable when troubleshooting or fine-tuning a saw’s performance.

For beginners, manually filing saw teeth can be an excellent way to learn the fundamentals of saw sharpening. Once those skills are mastered, the Foley hand saw sharpening machines can serve as a time-saving tool that still allows for hands-on involvement in the process. Here are some of our articles & videos to help you learn to sharpen a hand saw without machinery:

• How to Sharpen Hand Saws for Woodworking
• SHARPENING & HONING SUPPLIES
• How to Restore an Antique Back Saw

Conclusion

The Foley Retoother is a testament to the ingenuity and craftsmanship of an earlier era, providing a mechanical solution to a task that was once done entirely by hand. While saw sharpening by hand is still a valuable skill, the Foley machines offer a level of speed, precision, and consistency that is difficult to achieve through manual methods alone. For those who are serious about maintaining their saws, the vintage Foley machines are tools that can greatly enhance both the efficiency and quality of their work.

Though these machines are no longer in widespread use, they can still be found online and remain highly regarded by those who use them. Whether you’re a professional saw sharpener or a hobbyist looking to improve your skills, the a Foley saw sharpening machine is a tool worth considering. They represent a bridge between the traditional, hands-on methods of saw sharpening and the efficiency of modern technology, making it a valuable addition to any workshop.

About Tom Calisto

Tom Calisto is an expert hand tool maker, furniture maker, and engineer, with specialty in making historical hand saws, hand planes, and other woodworking hand tools. 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.