Winter
08-25-2010, 09:46 PM
Ok folks, I figured I'd do a walkthrough of how I make these. Maybe some folk will give it a go.
Select sawblade and bend it to ensure it hasn't lost it's temper. If it doesn't return to straight, toss it.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife001.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife002.jpg
Next, i cover one side of the blade with masking tape and draw what I'm thinking.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife003.jpg
Using a dremel with cutoff wheel I cut the clip.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife004.jpg
Take the old grinder and shape the tang.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife005.jpg
Now you work with bare hands to ensure the blade doesn't get hot. Dunk it in water every time it feels warm.
Rounding the belly.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife006.jpg
Viola, blade blank.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife007.jpg
Angle grinder mounted with some allthread is how i rough in the blade bevels.
Simply draw the blade across the disk like you were sharpening a knife.
Continually inspect the blade and keep it cool.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife008.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife010.jpg
At this point, I switch to my cheap belt sander.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife013.jpg
60 grit. Refine the grind and clean the flats.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife015.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife017.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife020.jpg
Once you get it evened up and the edge is about as thick as a hair, switch to 120 grit and refine the grinds and blend the transition from the bevel to the flats until you get a full length burr.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife023.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife024.jpg
Now is when I bring the spine down to the point. If you profile the point during the grind you may round off your point.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife029.jpg
Sanding pad to remove the burr and the blade is ready for a handle.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife033.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife034.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife035.jpg
Handle time, hmmmmmmm.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife036.jpg
Antler , leather, and copper is selected.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife038.jpg
Slot the antler guard with the dremel cutoff wheel and drill the crap out of the back part.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife040.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife041.jpg
Fit's good. Notice I made the tang slimmer and ground notches in the tang for the epoxy.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife044.jpg
Everything fits and is ready for epoxy.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife045.jpg
Mix your 2 part 2 ton epoxy very well. Remember it has never been together before.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife046.jpg
Assembly with epoxy between everything. Get as much in there as you can.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife049.jpg
All clamped up and will be ready to finish tomorrow.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife050.jpg
Select sawblade and bend it to ensure it hasn't lost it's temper. If it doesn't return to straight, toss it.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife001.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife002.jpg
Next, i cover one side of the blade with masking tape and draw what I'm thinking.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife003.jpg
Using a dremel with cutoff wheel I cut the clip.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife004.jpg
Take the old grinder and shape the tang.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife005.jpg
Now you work with bare hands to ensure the blade doesn't get hot. Dunk it in water every time it feels warm.
Rounding the belly.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife006.jpg
Viola, blade blank.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife007.jpg
Angle grinder mounted with some allthread is how i rough in the blade bevels.
Simply draw the blade across the disk like you were sharpening a knife.
Continually inspect the blade and keep it cool.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife008.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife010.jpg
At this point, I switch to my cheap belt sander.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife013.jpg
60 grit. Refine the grind and clean the flats.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife015.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife017.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife020.jpg
Once you get it evened up and the edge is about as thick as a hair, switch to 120 grit and refine the grinds and blend the transition from the bevel to the flats until you get a full length burr.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife023.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife024.jpg
Now is when I bring the spine down to the point. If you profile the point during the grind you may round off your point.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife029.jpg
Sanding pad to remove the burr and the blade is ready for a handle.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife033.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife034.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife035.jpg
Handle time, hmmmmmmm.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife036.jpg
Antler , leather, and copper is selected.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife038.jpg
Slot the antler guard with the dremel cutoff wheel and drill the crap out of the back part.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife040.jpg
http://img.photobucket.com/albums/v238/w6f7/sawzallknife041.jpg
Fit's good. Notice I made the tang slimmer and ground notches in the tang for the epoxy.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife044.jpg
Everything fits and is ready for epoxy.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife045.jpg
Mix your 2 part 2 ton epoxy very well. Remember it has never been together before.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife046.jpg
Assembly with epoxy between everything. Get as much in there as you can.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife049.jpg
All clamped up and will be ready to finish tomorrow.
http://img.photobucket.com/albums/v238/w6f7/sawzallknife050.jpg