Materials: styrofoam, lacquer thinner, vaseline, epoxy, fiberglass, carbonkevlar, epoxy, saw blade, matte black paint.
Tools: japanese saw, P40 sandpaper, latex gloves, angle grinder + cut off & grinding wheel, shop torch, clamps.
Step 1: Mold
Molds can be made from styrofoam or other similar material. I simply cut the rough shape using japanese saw, then smoothed them to shape with P40 sandpaper.
Step 2: Handles
I covered molds with vaseline so they won´t stick to resin. Then I covered them in epoxy and put on one layer of fiberglass, one layer of carbonkevlar and coat of epoxy.
Later, as the resin has hardened, i poured some lacquer thinner on the molds to dissolve them.
After I made sure that all remains of mold are gone, I cut the handles to right thickness using cut off wheel and drill press to maintain flat bottom.
Step 3: Filling
To fill in the cavity in handles I first cut carbon fibers into very fine, almost powder like, pieces. Then I made some epoxy and added carbon fibers making sure that they are well saturated with resin. After thorough mix up I poured the paste into hollow handles.
Step 4: Blade
I cut the rough shape from old saw blade using angle grinder and cut off wheel. Then I used angle grinder with grinding wheel to make required shape.
After the grinding I quenched the blade using shop torch and bucket with water.
Later I spray-painted the blade with matte black paint.
Step 5: Assembly
With all part ready I roughed the surfaces with sandpaper and cleaned them with lacquer thinner for better bond. Then I used epoxy to glue the handles to the blade . I clamped them together using spring clamp, making sure they are in correct position.