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Warbow arrows

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RobertofGwent:
I'm making some EWBS Standard arrows and was wondering whether anyone else uses only hand tools to cut the horn inserts? I don't have anything that cuts a wide enough slot for the horn inserts and have to spend a long time widening the gap with files and sandpaper. Currently I use a tenon saw, but it's still quite slim. Ideally I'd like to do as much as possible using traditional tools only - I know it's quite mad, but that's what I'm interested in. Can anyone suggest a saw that will produce a wider cut? I suppose it would be just under the 2mm mark.
R

WillS:
I use a mini saw that's in a multi-tool like a Leatherman.  Works perfectly as it's short and easy to control, and gives an almost exact fit.  I use sandpaper or a mini file to perfect it.  Once you get a routine going, it doesn't take too long.  I can get through 24 arrows in about 30 mins - 1 hour using just the mini saw and file.

I do know that you can tape three hacksaw blades together, the middle one leading and the outer two backwards, and that gives you an almost perfect sized slot.  I've used the three hacksaw blade method a couple of times and while it works pretty well in terms of size, I find it pretty tricky without a jig to keep the slot as straight as possible.

RobertofGwent:
That's true - I also find hacksaws too shallow to keep straight very easily. The number of small teeth is useful though, to keep the cut fine.

WillS:
Have you tried using a tile saw?  Most people use them for the string nock, but they're about 2.6mm diameter so can't be far off. 

adb:
Tape 3 hacksaw blades together. Works great, and cuts the perfect width slot.

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