David Wittner
During its heyday, there were nearly 70 sawmakers in Sheffield, England. Today there is only one. Beyond saws, hundreds of shops produced a variety of woodworking tools for every trade but as with other industrial cities, the times have been cruel to Sheffield. However, all is not lost. The city is fighting back and going through a revival where old factories are being re-purposed into apartments, shops, and restaurants. As the city works to redefine itself, one firm, Thomas Flinn & Co., continues to make handsaws in the Sheffield tradition.
Founded in 1923 by Thomas Flinn, the present company has been in the Ellis family since 1936 when Frank Ellis bought the business from Flinn after apprenticing and working there since he was 14. Franks son, Frank Phillip Ellis, joined his father in the business as did Frank Phillips eldest son, Christian, and daughter, Katie. This is truly a family owned and operated enterprise.
Upon arriving at this modest factory, I was cheerily greeted by Christian who quickly admitted that they dont get many visitors and dont give many tours. I thanked Christian for showing me around the factory and explaining about the industry, handsaws, backsaws, and the product lines.
My tour began in the woodshop where raw boards of English elm, American black walnut, and beech are turned into a variety of handle types. A small CNC router is the only thing that comes close to automation in the factory. It is used to roughen out the handles. Before this tool was acquired, each handle had been cut individually using a bandsaw. This is still used to cut intricate details on the backsaws’ open-handled handles. Each handle is then refined one at a time, bringing it closer towards its final form before being sanded.
I noticed a small box containing a jumble of handles and offcuts. Chris pointed to these as rejects. We have no quality control department that pulls saws randomly from the production line for inspection, Chris chuckled. Frankly theres not really a production line. Each saw is made individually and inspected throughout the process. Any defect found during the manufacturing process is immediately discarded, regardless of whether it has reached its final stage. This is part of the beauty of Thomas Flinn & Co. saws. Every saw, regardless its grade, is hand-made one at a.m. To maintain efficiency and keep down the cost of the final product, some parts are made in batches, cutting out handles or saw plates for example, but each saw is assembled and finished individually. Higher-end saws such as those of the Pax 1776 line, are hand sharpened, have handles that are shaped and sanded by hand and theyre given a hand-rubbed oil finish. It is almost like holding one of these saws.
We moved from the woodshop to the metal shop, where we found a wide range of industrial machines. The majority of machinery presses, shears, and other tools date back to Thomas Flinn’s shop in the 1920s and 1930s. Chris showed how two saw plates are made from one width of steel and punched holes to attach the handles. The saw plate will be next taper-ground and toothed before being sharpened, sharpened, and set. Thomas Flinn & Co. makes their saws using machines, but it is not automated. A craftsman makes each saw one at a time.
Backsaw sawplates are cut from coil stock. An entire coil of steel is sharpened and toothed in a room that contains filing and saw toothing equipment.
The blades are then trimmed to the desired length.
sorted. Then we returned to the main metalworking shop, stopping at the hydraulic press to fold the brass bar stock into the saws back. The width of the sawplate determines the aesthetic dimension of the bar stock. Chris is proud of the saws that not only feel and cut well, but also look great. Stepping into another part of the metal shop, Chris gave the sawplate a quick pass over a grinding wheel to remove any burrs, then deftly drove the sawplate into the back with a special purpose mallet.
From there, the saw plate gets its etch and a handle.
Handles are determined by grade, as is the finish and type of saw nut. High-end saws in the Pax 1776 line get English elm handles, solid brass saw nuts, and a hand-rubbed Danish oil finish. Lower- and mid-range saws, such as the Lynx and Roberts & Lee lines, are handled with either walnut or beech, have brass plated saw nuts and a spray- applied finish. Still individually made and worked by hand, the lower- and mid-range saws have less hand finishing.
Chris pointed out that the best way to reduce costs is to differentiate saws by the materials used and the degree of hand finish. This allows for a higher quality handsaw that is still affordable to woodworkers. Let me reiterate, regardless of grade, all Thomas Flinn & Co. saws are made in the same way and are of high quality. The difference comes in the details and the feel of the saw in your hand.
Part of the beauty of Thomas Flinn saws is that each saw is made to order. It is easy to customize your saw. Chris said that he prefers this method. He prefers to make one of pieces for individual customers rather than batches of saws, although the latter is a more reliable source of income. According to my knowledge, only one component of the saw is outsourced: the turned handle for the gentleman’s saw.
At one time the handles were turned in house, but better and more consistent results were found by turning to a woodturning shop a few doors down the street.Were not woodturners Chris said,were sawmakers.
Staying local is part of Thomas Flinn & Co. efforts to promote Sheffield tools and tool manufacturing. Originally the company sold only wholesale. Then one day it received a call from a man who wanted to buy a saw. Not wanting to turn the man away, he and Chris settled on a fair price and Thomas Flinn & Co.s retail business was born. The internet was a great way to increase sales. The World of Woodworking, a retail website (
The most amazing thing about this small factory of 2,000 square meters, which is filled to capacity, was the fact that it produces nearly every wood-handled saw in England. Thomas Flinn & Co. are the only premium saw manufacturer in the United Kingdom. Next time you visit your favorite tool seller and contemplate the Pax 1776, Garlick (Lynx), Roberts & Lee, Jesse Lane and William Reaves, handsaws remember that each one was individually made in this factory by one of four men who loves making saws.
