I am not responsible for any injuries inflicted on you or anyone else by the use of this weapon. By continuing you agree to the following:
1. You will hold me harmless
2. You will follow any state or federal laws regarding this weapon
3. If injured, you will not follow suit
Make at your own risk.
Step 1: Gather Materials
All materials can be bought at your local hardware store.
You will need:
<12"x1"x1/8" piece of Aluminium (1x)
Bolts and nuts you want to use, plus four washers for the pivots, I use a total of six bolts for my balisong
A blade (either make one, or salvage one from another knife)
Then get your tools:
Cobalt drill bits (if you plan on using a salvaged blade)
Some taps for the bolts (optional, though they make your job much easier)
Tool oil (needed for drilling hardened steel without ruining the temper, in other words, use if you are salvaging the blade)
Sand paper (also optional, just helps in the finishing process)
Step 2: Measure
Then, using the square, draw a line from that mark to the other side of the aluminium.
After that, mark the metal at the halfway point and draw a line down the middle, again, utilizing the square for a perfectly perpendicular line.
Step 3: Cut
Cut along the line you made first.
Now re-vise it and cut along the other line.
You should now have two pieces that are .5" wide, ~4" tall, and 1/8" deep.
Repeat steps 2-3.
Step 4: Drill
Drill on that mark, making sure your hole fits your bolt loosely, but not so loose that it rattles.
Repeat for all four pieces.
Step 5: File
Step 6: Make Spacers
Cut out the spacer. Remember, aesthetics are not the goal, these won't be seen.
Make two of them.
Step 7: Drill
Make sure your bit is exactly the same size as the screw you wish to use, you will not be putting a nut on these.
Drill two holes in each handle to match the spacers. Make sure your blade can still fit!
Repeat for the other spacer/handles.
Step 8: Prepare the Blade
Pick spots for the two pivots, and the two tang pins.
SLOWLY drill the spots, liberally apply oil.
If you are using a salvaged blade, drill out the place where the thumb grip is. The grip should just fall off.
Wipe the blade clean.
Step 9: Sand
Step 10: Assembly
Tap out the holes for the spacers, or don't, but it makes the next step much easier.
Put a screw in each hole for the spacers on one handle piece. Next put a bolt in the pivot of that same handle piece. Now put a washer on the bolt on the side that the blade will contact. Then put the blade onto the bolt. Now install the spacer. Do this by aligning the screws with the holes on the spacer, then screwing them in. Put another washer on top of the blade. Then put another handle piece on. Place it first on the pivot, then tighten the screws so that they go through both handle pieces, sandwiching the spacer in between. Put a nut over the bolt and tighten.
Now repeat for the other side.
Step 11: Add the Tang Pins
Step 12: File
Step 13: Tie Up Loose Ends
Install the latch now. The easiest way of doing this is to epoxy two rare earth/Neodymium/NdFeB magnets to the inside of the handle pieces. The other way is much harder, which is to make a T latch, I won't elaborate on that, it's just not practical.