Value Thoughts on Engineering, Materials & Craftsmanship
Last August John Economaki conceived of a way to safely make repetitive cuts using a hand saw. The first prototype involved a Japanese handsaw held upside-down in a wood vise. The second permutation was a simple butcher-block with miter gage slots. This evolved to ball bearing linear tables (see photos below) and a tilting blade. The noise from the ball bearings, in addition to cost factors led to yet another version. All in all, there were over 40 digital (computer) versions and four different working prototypes built. Eleven months later, the Jointmaker Pro is being released for manufacture. Barring surprises, the production time for the first edition will be 3 months and units will be delivered in November. (I just received a comprehensive list of changes from the prototype I worked on when I was in Portland and I will note this in a later update.)
If you glance back at the assembly section you have to notice the engineering aspects of a device representing twenty-five years of tool design experience. The Jointmaker Pro features the same sensibility & engineering that has gone into every plane, square or measuring device BCT produced. The Jointmaker Pro works for a reason; it is the singular passion of an out-of-the box thinker and it works unlike anything I have ever seen - or used.
It is my desire to provide FOG members with an accurate assessment of this new tool based upon my unbiased experience in Portland working with one of the prototypes. As part of my research, I have read many of the discussions on Internet forums regarding the Jointmaker Pro. Outside of positive comments, most of the negativity involved the selling price and/or, the tool is "cheating". Here's a sampling;
"the concept is innovative and you can't deny the results. But it takes away the portability factor of the handsaw, and the price, hmm! Besides it doesn't have the tactile quality of a hand tool that draws most of us to them."
"At this price, I would like to see the blade be set to rise automatically each stroke, vs. having to push, then hand crank up the blade, over n over. I think it would add tremendously to the "usability" factor."
"Just curious.... If anyone uses this to cut dovetails, would we still call them "hand-cut" dovetails? And if so, how do we distinguish those from ones cut using just saws and chisels"
"Over the next few weeks, I will be building more of these tables and I could really use a saw like that."
"Where's the cord"
"I had the chance to see and use the BC saw in person. The inventor gave a demo to a group of us. All I can say is you have to use it to understand. He came up with the idea to cut the very small and detail moldings made by the small multi hand plane they sell.
All i can say is I don't care how good or expensive a hand saw is or how skilled a woodworker is. You will NEVER make as clean and straight a cut as this saw will. This is from Hands on experience. The cut on end grain is smoother than glass. That said I think I will hold off for the $19.99 Harbor Freight unit LOL!!! "
"I just can't cut small pieces on a powered miter saw like that!"
"A Challenge? Be interesting to watch a you-tube video of Rob Cosman hand cutting a dovetail vs. someone using the Bridge City "hand-cutting" machine. Bet Cosman would win (time-wise)! Maybe his cuts wouldn't be quite as precise--but you wouldn't be able to detect that once the joints were assembled."
"I also do model railroading and radio control airplanes. A saw like this could cut down the time required to build a plane (like my 1/4 piper cub) by 90%!!! I think something like that would be worth about $600, but I could imagine paying that much for it. I'd also write some letters to the company trying to see if I could get a discount somehow."
"At first hand appearances, I would have thought $99 or so, which makes me now wonder where they used the gold plating, since I can't see any in the photos"
...taken on a philosophical level, a Poet Sage once stated;
"Price is relative.
As long as a tool fits a need it can be priceless.
I would have gladly paid a thousand dollars for an adjustable wrench
the day I was stuck in the Painted Desert."
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After my two-day experience with the Jointmaker Pro, I sat down with John and Michael over dinner and a beer and among other topics, cost bubbled to the top. They were both frank about managing costs and I can share the following for those who think this tool is obscenely overpriced;
1. The tool weights approximately 32 pounds - most of this is in aluminum plate which is almost $4.00/lb.
2. For those of you that are not familiar with anodizing, it is not inexpensive and adds over $100 in cost to the unit.
3. The screws, nuts, knobs, gears, and washers, IN BULK cost the company almost $50.
4. John and Michael are very proud of the fact that with the exception of the Japanese made blade, the Jointmaker Pro is an American product where all involved make a living wage.
These are the only costs I agreed to share. But you can see, without turning on a lathe, or milling machine, building fixtures, or adding a profit margin, or any attempt to recoup R&D costs, or adding the fees for patents, there is simply over $250 in raw material/finishing expenses. So for those who are anxiously awaiting the Harbor Freight version for $45, I for one just don't see this happening - EVER. A good dozuki saw runs $30-$90.
We talked about CNC machining verses water jet cutting and John explained to me that the surface from a water jet cut still needs to....."be cleaned up with a milling machine for the tool to work smoothly. With the high speed milling machines used today, it makes no economic sense to do both."
An engineer I know, who works for a well known research laboratory, read my review and asked me why John hasn't used off the shelf ceramic glides in place of the custom made nylatron glides or to use ceramic components in place of other machined aluminum components. John replied "ceramic glides are not inexpensive and don't address the negative feed issues this tool creates during use. However, if he has knowledge of such a solution, please have him contact me."
As to the "cheating" aspect that has come up on forums, one needs to understand that a chisel is still required for waste removal. We discussed this at length and John does not feel bound by traditional techniques, he is focused on creating a positive user experience in a society where practice time is either in short supply or impossible to justify.
One aspect of the Jointmaker Pro that would be familiar to long time Bridge City Tool customers is the 100% satisfaction guarantee that Bridge City Tools maintains. It states that... If you are not 100% satisfied with your purchase, simply return the item WITHIN 90 DAYS after receipt for a merchandise exchange or full refund. I don't mean for that to sound like an advertisement, but a fact is a fact.
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One late breaking news item...
Bridge City is going to offer the Jointmaker Pro pre-assembled for an additional $249. This cost includes the labor and added packaging expenses and is in direct response to my comments that there are potential customers who would greatly appreciate this service. (this would not include the actual shipping costs)
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And this just in.......
This review would NOT be complete without a list of the changes I just received from John Economaki at Bridge City Tools outlining the changes from the Jointmaker Pro prototype to the production model coming out within 90 days.
So here it is......
After three months of using and demonstrating the Jointmaker Pro prototypes, the following changes have been made -- the production version is being released for manufacture next week.
Front and Rear Plates
> Width changed from 16.25" to 13.7"
> 10 Non-threaded holes added, three on each side and four along the top (each plate)
for shop-made accessories (i.e., auxiliary supports for long stock, stop rails, etc).
> Grooves for square nuts and finger stops tightened to eliminate play.
> Rear plate now accepts finger stops
> Crescent cutout at the top of each plate removed for new linear rail locations.
Top Plates & Linear Motion Carriage Changes
> Top plates: width changed from 9.875" to 8.01", Length changed from 10.25" to 10.5"
> Nine threaded holes added to facilitate user-made jigs and fixtures
> Rubber bumpers increased in size from .5" Dia to .750" Dia.
> Linear guides changed from Nylatron to acetyl. Eliminates swelling to do humidity changes and increases lubricity.
> Linear guides lengthened to improve function with one hand use.
> Linear guides shifted closer to blade to improve function with one hand use.
> Dovetailed ways and bottom rails shortened by 1-1/2"
> Top plates will be laser etched to indicate danger zone when blade is tilted.
> Fence locking slots redesigned to for ease of use and quicker changes.
Engineering Changes
> Crank handle is now locked with a jam nut as opposed to a set screw
> Thrust bearing added to front shaft to improve gear train operation
> Acetyl travelers used for blade tilt redesigned to improve user calibration process
> Acetyl travelers are now identical allowing for finger stops to be used on the rear plate.
> Blade guide uprights are more robust for increased support
> Blade guide uprights are now dovetailed at the top to receive the blade guides
> Blade guides are dovetailed to slide in blade guide uprights?this makes it impossible to miss-align the guides in relation to the saw blade.
> Blade pitch center changed to improve rigidity
> Pitch block redesigned to eliminate play.
> Pitch screw now has a knob for finer and easier adjustments
> Acetyl travelers in front and back plate redesigned to ease assembly.
> Cup washers eliminated from saw spine to ease blade changes.
> Dovetailed ways are now separated by three spacer rods as opposed to two. This will ease table alignment and accuracy.
> Linear motion geometry completely redesigned for one hand use with both tables bridged.
Fence and Clamp Block Changes
> Fence locking levers replaced with knobs to remove risk of levers hitting blade accidentally. This also improves ergonomics in use.
> Universal clamp blocks redesigned for both flat and trap clamping as well as square
and miter cuts.
> Sacrificial fence locks to supports with one dovetail nut per side as opposed to two?speeds set-ups dramatically.
> Dovetail nut changed from 60 degrees (inclusive) to 28 degrees. Sacrificial fences can be user made with readily available 14 degree router bits.
