Knife From Sawzall Blade

4,536

69

7

Posted in WorkshopMetalworking

Introduction: Knife From Sawzall Blade

About: Retired Firefighter 1966 to 1986; Retired Wheat Farmer 1987 to 2003. Drapery Sales 1969 to 1987. 17 year Quintuple Heart Bypass Surgery Survivor; 14 year Melanoma Cancer Survivor. 81 years young.

I've made a few knives in recent years and had wanted to make one from a saw blade. Since I'm almost 81, I cannot get to my shop as often I once did. Here is a simple little knife I made recently that I like a lot.

Step 1: THE SAW BLADE

I started with this worn out Sawzall blade. I shaped it with a bench grinder, a high speed air disc grinder & a 4" wide bench mounted belt sander.

Step 2: THE HANDLE

I had this deer antler left over from another handle I made from the crown. https://www.instructables.com/id/Turquoise-Insets-M...

I cut out a straight piece of the diameter I wanted for the handle. Measure 3 times, cut once.

Step 3: ATTACHING HANDLE TO BLADE

I did very little to the antler except drill a hole with a 1/8" bit and enlarge it to accept the tang of the blade. I cemented it together with 2 part epoxy.

I polished it slightly with polishing wheel & medium compound. I didn't want it glossy; only semi glossy.

Step 4: INLAID TURQUOISE ON END OF HANDLE

To jazz it up a little, I decided to add an inlay of turquoise to the handle. I did an Instructable on inlaying and it's too involved to cover here. If you want more info on inlaying go to:

https://www.instructables.com/id/Turquoise-Insets-M...

Step 5: THE FINISHED KNIFE

This turned out to be one of my favorites. it is small and easy to use. The handle has a slight downward shape and fits my hand nicely. The blade required no shaping except rounding the end and sharpening it. It had already been heat treated, I suppose. It's not as big as my huge Bowie made from car leaf spring but it's a nicer size. https://www.instructables.com/id/Bowie-Knife-2/ It's almost the same size as our set of steak knives

Try making one from a Sawzall blade. You'll enjoy making and using it or giving it as a Christmas gift as I am doing with this knife. I'm sure my grandson will appreciate it and save it as a family heirloom.

Share

    Recommendations

    • Science of Cooking

      Science of Cooking
    • Pocket-Sized Contest

      Pocket-Sized Contest
    • Microcontroller Contest

      Microcontroller Contest
    user

    We have a be nice policy.
    Please be positive and constructive.

    Tips

    Questions

    7 Comments

    Very nice! I've been thinking about doing that for ages. I actually have some blades on the workbench that I was planning on using to make a fillet knife.

    2 replies

    The Sawzall blade finished out very nice & didn’t take long.

    Thank you ArthurJ5. If you make one, publish an instructable on it. I will warn you though, it's habit forming. It's like eating potato chips; You can't make just one.

    user

    Very nice Greydog! Simple, yet has an elegant appeal and the inlay... icing on the cake! I'm going to check out your other posts... keep on trucking!

    1 reply

    Impressive, it's not only fun to make but a great way to recycle old blades. I have the tools needed for this project, might be a fun project for this month!

    Also, i really like the fact that you're still in the workshop at your age!

    1 reply

    Thanks inhuzinha. Try it & you’ll get hooked