Bosch 1591EVS Barrel-Grip Corded Jigsaw review

The Bosch 1591EVS is an earlier U.S. corded barrel-grip jigsaw with a side slide on/off switch that locks on. It shares the documented 120 V, 6.4 A motor, 500–2,800 SPM range, one-inch stroke and four-position orbit selector with the top-handle 1590EVS, but the handle and switching arrangement are real configuration differences. The sources reviewed here do not settle the 1591EVS blade-shank interface. Bosch's later EVSL catalog package also conflicts with the old manual on wood and aluminum depth figures.

Barrel grip and side switch distinguish this body

Bosch labels the 1591EVS slide switch at the side of the motor housing. Slide it forward to turn the tool on and back to unlock it; the switch itself locks in the on position for continuous operation. That differs from the 1590EVS, whose manual shows a trigger and a separate lock-on button. Both saws have a six-number variable-speed dial and the shared manual describes constant-response circuitry, precision-control guides, tool-free blade change, four orbital positions and a beveling footplate. These features do not establish equal ergonomics or cut results, and no personal handling or test is claimed.

The product image is a seller-listed 1591EVS specimen photographed in an older hard case. It helps distinguish the barrel-grip body but does not prove the seller's package, the condition of another offered saw or whether the case pictured was originally supplied with that exact listing.

Do not assume a shank type from the family name

The shared manual describes a one-touch blade clamp, insertion into the plunger and a blade-ejection lever, but does not identify T-shank or U-shank compatibility. Bosch's 2007 catalog explicitly names a T-shank machined plunger for the top-handle 1590EVSK; that exact statement is not transferred to the 1591EVS. The 2012/2013 catalog's “same features as 1590EVSL” wording on the 1591EVSL page is not precise enough to prove a particular blade interface when the models have different bodies and switches. If you already own a blade set, inspect the exact saw and its manual before treating it as compatible. This assessment intentionally does not put the 1591EVS in either shank-filter result.

The manual's action chart is practical but not a performance guarantee. Position 0 is suggested for hard materials such as metals or thin sheet; position 1 for softer materials where cleaner cutting or delicate scrolling is desired; position 2 for medium-density work such as harder woods or particle board; and position 3 for soft materials such as wood or plastic when speed matters more than a clean cut. Bosch calls the chart a guideline and recommends testing on scrap. For wood or plastic the blower may be switched on; for metal, coolant or dust collection, the manual says to switch it off.

Published capacity tables conflict

The 2004 manual gives shared figures for the 1590EVS and 1591EVS: 5-3/8 inches in wood, 3/4 inch in aluminum, 3/8 inch in steel and 1/8 inch in stainless steel. The Bosch 2012/2013 catalog lists the 1591EVSL barrel-grip kit as having the 1590EVSL specifications above it: 5-5/16 inches in wood, 7/8 inch in aluminum and 3/8 inch in mild steel. It does not say why the wood and aluminum numbers differ or tie those figures to a particular nameplate/revision. The finder therefore does not use a single capacity threshold for this body. Verify the offered model and its matching manual rather than treating one source's maximum as a tested or universal result.

External extraction has a hardware boundary

Bosch says the chip blower is for wood, plastic and similar material that makes sawdust, while metal work, cooling agents and a dust-collection accessory call for the blower to be off. The shared manual treats the vacuum adapter and dust shroud as optional and says the adapter must be used with the shroud when connected to a vacuum. Bosch's 2012/2013 accessory page lists separate JA1005 extraction kits as compatible with the 1590EVS and 1591EVS series; the kit components are a dust hood, vacuum adapter and suction nozzle. The manual also tells the user to remove the dust shroud if fitted before changing the shoe angle. A bevel shoe exists on the 1591EVS, with adjustments up to 45 degrees in either direction, but this assessment does not combine a connected external-vacuum setup with beveling in one finder plan.

The optional JA1010 is a separate circular/parallel cutting guide, not a dust adapter. Bosch's current U.S. accessory page expressly lists both the 1590EVS and 1591EVS among compatible jigsaws; it says the guide supports parallel offsets and circle cuts within its stated ranges. That compatibility page does not say the guide is included with a saw or replace the user's need to check the exact accessory and manual.

K and SL are package variants, not different 1591 bodies

The 1591EVSK is the older case-included kit named in Bosch's 2007 catalog and in its 2024 service program. The 1591EVSL is the later L-BOXX-2 configuration. Bosch's 2012/2013 catalog lists the SL package with an L-BOXX-2 and insert, three assorted blades, a non-marring footplate overshoe and anti-splinter insert; it lists dust-collection attachments separately. A historical Sunrise Tool page for the exact 1591EVSL also lists a JS1005 dust-collection kit among its advertised inclusions. That retailer listing conflicts with the Bosch catalog's optional-attachment treatment, so this review does not claim that JS1005 was universal to every 1591EVSL carton. The plain 1591EVS model label identifies the barrel-grip body but does not tell you which suffix package a seller is offering. Confirm the exact suffix and written contents, especially when the case or accessories matter. A service-program price line or an old seller listing is not current retail stock or a guarantee of parts or warranty support.

The same retailer page pairs the 1591EVSL name with a listing image of a Bosch barrel-grip saw beside a blue case. The photograph shows the body and case, not the blades, inserts or dust kit; it cannot settle the conflict over the JS1005 or prove what a current or used seller will ship.

Who should compare this version

The 1591EVS deserves separate consideration when a corded barrel-grip body and locking side slide switch fit the intended handling preference. The 1590EVS is the top-handle/trigger alternative, and it has specific Bosch catalog evidence for T-shank blades; the 1591EVS shank evidence remains open. Both have a blower, orbital chart and bevel shoe, but a vacuum accessory changes the setup and does not eliminate the need to match the blade to the work.

This is a source-based assessment, not a hands-on review. It makes no claim of ownership, test cuts, comfort, measured accuracy, vibration, current availability, price, rating or seller-unit condition. The exact-name CPSC lookup saved for 1591EVS returned no records, but a single-name search is not comprehensive recall clearance.

Sources and method

• Bosch 1590EVS/1591EVS Operating/Safety Instructions (shared specifications, model-specific switch distinction, operating guide, blower, dust extraction and bevel instructions).
• Bosch Saw & Benchtop Tools & Accessories Catalog (2007 product entries; hosted by iFixit, where only a readable excerpt was available).
• Bosch 2012/2013 Power Tools & Accessories Catalog (page 210 SL package and capacity information; third-party-hosted copy of Bosch catalog content).
• Bosch JA1010 Jig Saw Circular and Parallel Cutting Guide (current accessory fit list including both body models).
• Bosch 2024 service program (repair-program reference only, not a current offer).
• Sunrise Tool historical 1591EVSL product page (retailer listing and paired image; its JS1005 inclusion wording differs from the Bosch catalog).