Introduction: Bottle Opener From Table Saw Blade

I made this bottle opener from an old table saw blade that had worn out and was sitting on my shelf gathering dust. The wooden handle is made from leftover Mesquite wood flooring that someone gave me. And the pins are just nails. I made this to get more practice working with steel and wood.

Here is a video link of me making this bottle opener.

Step 1:

I started by tracing the shape of a bottle opener on to the saw blade. I wasn't sure what the handle would look like so I just free handed a shape that I thought would work. Once I was happy I refined the shape with a blue marker so I would know where to cut the steel.

Step 2:

I used my angle grinder with a cutoff wheel to cut out the rough shape of the bottle opener.

Step 3:

I did some clean up and shaping on my 1x30 belt sander and used a cove file on the curved parts.

Step 4:

I tested the opener to see if it would work, at first it didn't so I had to modify the mouth of the opener. I used my angle grinder with the cutoff wheel and a round file to get the shape of the bottle opener just right. After these adjustments it worked perfectly. I also did any final sanding and polishing of the metal at this point. I used various grits of sandpaper starting with 150 grit and finishing with 600 grit.

Step 5:

I marked and then center punched the location for the pin holes. Then using my drill press I drilled the two holes.

Step 6:

Next using my drill press again I predrilled the holes through the wood handles. I used tape to keep everything aligned while drilling the holes.

Step 7:

I then traced the handle shape on to the wood and used my scroll saw to cut out the shape. This wasn't a perfect cut I left some room for error. It was mostly to get rid of excess material.

Step 8:

I used my angle grinder again this time with a flap disc to clean up the curve of the wood handles. I used my round file and sandpaper to further define the curve.

Step 9:

I used my 1x30 belt sander to do some of the shaping on the wood handles before gluing them on. Once they were glued this spot would be more difficult to shape.

Step 10:

I mixed some epoxy and assembled the pieces and used clamps to hold it together. I let this dry over night.

Step 11:

Once the epoxy was dry I cut off the excess pin material with the angle grinder cutoff wheel.

Step 12:

Time to shape the handle. I used my 1x30 belt sander to get the basic shape of the handle then I used a worn out sanding belt to refine the shape. Then I used various grits of sandpaper to smooth out the finish. I started with 150 grit and sanded up to 320 grit.

Step 13:

I applied 5 coats of a dark walnut Danish tung oil finish to the wood.

Step 14:

This is my attempt at trying to take some 'cool' pictures of the bottle opener. I hope you enjoyed the instructable.

Comments

author
mlawing (author)2016-07-25

Nice work! VOTED!

author
danthemakerman (author)mlawing2016-07-25

Awesome thank you for voting it is much appreciated.

author
3366carlos (author)2016-07-23

that's a heck of a bottle opener.

author

Thanks it definitely does the job.

author
sixsmith (author)2016-07-21

very nice, I might make one myself! quick tips, a rotary tool, such as a dremel, will really help getting into those tight spots, and using the pins for alignment and a piece of cloth carpet tape (high strength double stick tape) you can cut both handles at once.

Also, this is very similar in construction to a knife, and you've got a fair amount of leftover steel from which you could make a knife, point being, check out Walter Sorrells on youtube, he's got some great info on knife and knife like stuff.

author
danthemakerman (author)sixsmith2016-07-21

Thank you for the comment and the advice. Walter is awesome I like his no nonsense approach. I'm currently building a mini forge for heat treating I will probably make a Gough jig too and then after that will come my first knife. Thanks again for the advice.

author
sixsmith (author)danthemakerman2016-07-22

no problem, oh, I also voted for you. Good luck with the mini forge, I'm guessing coffee can gas?
between that angle grinder and belt sander you ought to be able to hog off a lot of metal before going to files for final profiling.
Best of luck with the contest!

author
danthemakerman (author)sixsmith2016-07-22

I got a really good deal on some fire bricks, so I will be using those with a blowtorch. I tested it yesterday, and it works and bonus it didn't explode! Thanks for the vote.

author
Buso (author)2016-07-22

Great Instructable. A Winner!

author
danthemakerman (author)Buso2016-07-22

Thanks glad you liked it.

author
the ginius (author)2016-07-21

Totaly awesome!!!!

author

Thanks.

author
Foskifo44. (author)2016-07-21

Looks awesome ! Fav'ed it for next make :)

author

Awesome!

author
Make_This (author)2016-07-21

Hefe Weizen. Thumbs up!
Oh -- the opener is very nice too. !

author
danthemakerman (author)Make_This2016-07-21

Haha thanks.

author
Wolfbane221 (author)2016-07-21

really cool!

author

Thanks!

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