Assuming you have access to a CNC Plasma or Laser cutter (Lasers being highly preferred) to cut a blade with, the hardest part of creating a Mechanics Machete is actually creating the handles and finding the right sized sheath.
So to save on time and add simplicity the Mechanics Machete was created to use the handles and sheath from a store bought machete. Specifically, it uses a Harbor Freight tools machete (http://www.harborfreight.com/18-inch-machete-with-nylon-sheath-94154.html
), which is both affordable, and features plastic handles that won’t rot like wood ones can.
The blade profile needed to create the mechanics machete either by cutting the hexagon profiles in the stock 14GA carbon steel blade that came with the machete or, more preferably by cutting a new blade out of stainless steel can be found in the DWG file attached to this page. If you don’t currently have a CAD program installed to view/edit the DWG files, I recommend the free Draftsight DWG editor (http://www.3ds.com/products/draftsight/overview/
The attached DWG includes the blade profile and hexagon cutouts for 9mm nuts/bolts up to 25mm nuts/bolts in 1mm increments. Due to the 1mm increments, this “Metric” blade also works with all major “English” nut/bolt sizes up to 1inch.
You can of course make your Mechanics Machete using any brand of off-the-shelf machete you choose. Just simply take off the handles, trace the blade on graph paper, and then draw it in some sort of DWG editor. Then when you have the profile drawn take the specially drawn sockets from the attached DWG and add them to your blade design.
If you plan to draw your own sockets, you should note that you can’t just draw plain hexagons as Laser/Plasma cutters typically don’t like to create sharp corners. So to fillet the corners without affecting the base “Wrench Size” you have to draw a 1.5mm(1/16in) diameter circle in every corner and fillet it into the hexagon with .75mm(1/32in) radius fillets. Also if you want to make a cutout for a 32mm sized nut, you can’t draw the hexagon exactly 32mm as such a perfect fit will most likely not work. Instead, you need to add .05mm to .1mm to the base nut size. The easiest way to figure exactly how much to add is of course to find a 32mm socket or wrench and measure it with a pair of calipers.