DIY Large Aluminum Bucksaw

Nice saw!  How is the stability?

A notch away from perfect, the flatbar will bend if I over twist the string, but I find if I direct the bend against the way that the tension pin wants to spin, it counters the flatbar from over bowing. Tubing in the cross bar would be better, but more complex to mount maybe, and heavier?  Still dreaming on a design there for the packsaw version.

The adjustable bottom portion of a crutch is a thicker, stiffer extrusion that the long tubular sections.  I suspect it would be stiffer and possible lighter than the flat you’re using now.  Do you have a length and weight on the flat bar.  I’ll check length and weight on my suggested bit.

I keep a few crutches around at all times for raw materials.  Usually, I can’t buy a pair at Salvation Army because if I come up to the counter with a pair or two, both they give them to me and encourage me to take more if I want, because they are always piling up.

Hey I did a quick weight in for you. 16.5″ flatbar was 2.4oz and one 17″ aluminum tube with the paracord dangling that I currently have tied in is 2.7oz

Holes could be drilled in tubing with lesser degradation to structure to cut some weight. Got pictures but they load in upsidedown.