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Thread: Making a sawzall knife (pic heavy)

  1. 08-25-2010, 09:46 PM #1
    Winter
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    Default Making a sawzall knife (pic heavy)

    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.
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    Next, i cover one side of the blade with masking tape and draw what I'm thinking.
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    Using a dremel with cutoff wheel I cut the clip.
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    Take the old grinder and shape the tang.
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    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.
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    Viola, blade blank.
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    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.
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    At this point, I switch to my cheap belt sander.
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    60 grit. Refine the grind and clean the flats.
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    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.
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    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.
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    Sanding pad to remove the burr and the blade is ready for a handle.
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    Handle time, hmmmmmmm.
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    Antler , leather, and copper is selected.
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    Slot the antler guard with the dremel cutoff wheel and drill the crap out of the back part.
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    Fit's good. Notice I made the tang slimmer and ground notches in the tang for the epoxy.
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    Everything fits and is ready for epoxy.
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    Mix your 2 part 2 ton epoxy very well. Remember it has never been together before.
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    Assembly with epoxy between everything. Get as much in there as you can.
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    All clamped up and will be ready to finish tomorrow.
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  2. 08-25-2010, 09:52 PM #2
    panch0
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    Nice WIP! I just might make me a fillet knife and use the back as a de scaler.
    -Frank

    Whether the knife falls on the melon or the melon on the knife, the melon suffers. (African Proverb)

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  3. 08-25-2010, 10:54 PM #3
    crashdive123
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    Well done Winter. Sent a little rep your way.
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  4. 08-25-2010, 11:39 PM #4
    rebel
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    Nice tutorial.
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  5. 08-26-2010, 12:00 AM #5
    Rockgod1619
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    Excellent tutorial!! This makes me want to make a blade soon, as the weather starts to cool off here!
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  6. 08-26-2010, 10:19 AM #6
    Winter
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    Done, except sheath.

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    Turned out pretty good for a rush job. Very light.

    This could all be done with files and sandpaper.

    Look forward to seeing someone give it a try.
    Last edited by Winter; 06-18-2014 at 04:20 PM.
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  7. 08-26-2010, 10:26 AM #7
    Justin Case
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    NICE ! well Done, Thanks
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  8. 08-26-2010, 10:42 AM #8
    canid
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    i like the personality of that knife. great buildalong and writeup.
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  9. 08-26-2010, 10:51 AM #9
    panch0
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    IS the spine hardened like the tooth side on these blades? If so then I AM going to make me a fillet knife that I will keep for personal use.
    -Frank

    Whether the knife falls on the melon or the melon on the knife, the melon suffers. (African Proverb)

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  10. 08-26-2010, 10:58 AM #10
    canid
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    i'm currently searching for info on the steel grades used in various recip. saw blades. the bi-metal blades might just be something like junk steel laminated with HSS; who knows. if anybdy has a good source for info on the matter, i'd love to know. i'll post something if i find anything usefull.
    Last edited by canid; 08-26-2010 at 11:06 AM.
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  11. 08-26-2010, 11:18 AM #11
    klickitat
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    Great stuff. This should really be a sticky. Anyone who has ever wanted to get started building knives or just wants to be able to build something for themselves, this is a great place to start. Nice job and nice set of pictures explaining things.
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  12. 08-26-2010, 01:49 PM #12
    crashdive123
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    That turned out great.
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  13. 08-26-2010, 02:21 PM #13
    Erratus Animus
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    I enjoyed that Winter ! looks good!
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  14. 08-26-2010, 04:15 PM #14
    rebel
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    If I could give another rep I would. It turned out great. I will have to give that a try. Thanks!
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  15. 08-26-2010, 08:57 PM #15
    Winter
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    Thanks all.

    As to the steel. It sharpens easily and dulls quickly.

    I did make some errors on this knife. The copper is a self adhesive copper tape and it warps badly as can be seen in the pics. had i used flattened copper pipe it would have turned out better.

    ETA- the guard turned out really good. The fork of an antler is pretty hard and marrow when it's that thin. I'll do some guards like tht on thicker knives in the future.
    Last edited by Winter; 08-26-2010 at 08:59 PM.
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  16. 01-17-2011, 01:41 AM #16
    shiftyer1
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    I made a blade out of a saw zall blade a couple years ago but never got around to the handle. Have you ever tried soaking an antler and just forcing the tang into the marrow? Thats what I intended to do, now that I have some free time maybe i'll finish it up.
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  17. 01-17-2011, 04:14 AM #17
    Winter
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    I have not tried that but I'd be concerned the water would never leave the inside.
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  18. 01-17-2011, 06:44 AM #18
    crashdive123
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    Quote Originally Posted by Winter View Post
    I have not tried that but I'd be concerned the water would never leave the inside.
    I agree. In addition to trapped moisture rusting the tang, I would think that the handle would not be able to be secured adequately.
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  19. 01-17-2011, 08:01 AM #19
    Rick
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    I somehow missed this whole thread. This is an excellent tut. Very nice job and I added a little rep as well.
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  20. 01-17-2011, 08:08 AM #20
    randyt
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    awesome thread and the knife turned out great.

    as to soaking antler and forcing the tang in this is a old method. basically the pith becomes a glue and hardens up after drying. care will need to be taken because the antler is brittle and can break. force the antler onto the tang.
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