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Make a kitchen knife out of an old circular saw blade!

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This is the second knife I have made. The first was more of a combat knife and can be found here. I've decided to make a kitchen knife for this time around. The knife was pretty easy to make, and was completely free! OK so enough chit-chat lets get on to making the darn thing!
 
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Step 1: Materials and tools used!

Tools used:
Angle Grinder with a cutoff wheel and a grinding wheel
Bench vice
Bench grinder
Jigsaw
Multiple clamps
A garden hose
An assortment of sandpapers
J-B Weld 
Scissors
A pencil and sharpie
A rasp and file
Safety goggles
If I forget anything I'll mention it in the steps!

Materials used:
Graph Paper
A cereal box or other source of cardboard
An old circular saw blade
A handle material (I used some wood I found in our garage. My dad says it's maple)
(Optional) Wood stain
I think that's about it! Same as with the tools though, if I forget anything I'll mention it in the steps.
Some cloth to cover the vice with so you don't mar your blade or handle.

Step 2: Drawing out your design!

Take your graph paper and you pencil and draw!  While your drawing imagine yourself holding the knife. The problem I ran into was getting the handle to a suitable length. Remember, you can do whatever you like, I chose to make mine a chopping knife, but you may want to make a paring knife, I don't care, make whatever you want!

NOTE: Make sure your design fits of the saw blade you will be using.

Step 3: Acquire said cardboard

You can get your cardboard from almost anything in your pantry, fridge, or freezer. Sadly I didn't have any empty boxes, so I ate breakfast! This was the last of the cereal in the box. The moral of the story? You're probably going to have an almost empty box somewhere!

Step 4: Cut, trace, and cut again!

Its time to get a cardboard knife, first take your cut out design (Wait, did I say to cut it out, No? Well cut it out now.) Then trace it on the cardboard and cut the cardboard design out.
blkhawk1 year ago
I noticed that you did not discuss heat treating your knives. Do you think that it is not needed?
Xthinker (author)  blkhawk1 year ago
It's not needed with these saw blades because they are already heat treated professionally.
There is a few reasons actually to still heat treat these knives yourself.

First and most important the factory treated them for the purpose of the original design which gave them tremendous longevity but no torsion resistance they were never made to bend. In a kitchen knife you are fine but if this was a camp knife where you needed to pry or twist this could easily compromise your knife.
Second is for ease of production by first annealing the metal you make it pliant and easier to shape cut and finish(less elbow grease and materials) making your finished product look alot nicer because you were able to buff out all the imperfections
Third and finally there is sharpening to consider the Rockwell on these blades is high enough that to get a good edge takes a bit of time and while it may keep it's edge longer when it does loose it's edge it will be a PITA to get it back.

I'm not saying go out and buy/make a forge for heat treating either a simple hand torch can get you through if you are patient but heat treating is something to consider. if you want to keep doing it your way but want a good blade with alot of spring and a good bit lasting power there is a half way method that does work here
Once you have your blade mostly formed put it in a vice blade end first with a wet towel around the blade. Use a torch and evenly on both sides of the handle work the metal just to the blue stage (grey is a bit too far it will be too soft) do this three times (you will have to sand off the scale) and be sure not to run into the blade yet. that will give the handle give so it won't snap under stress (don't quench it).Then flip it in the vise don't work about a damp towel on the handle you were protecting your edge. Start at the spine of the blade and work your torch towards the edge (never put the flame on your edge) we are looking for 2 colors this time blue on the side and a strawish color on the edge repeat 3 times on both sides(if you want a tip that won't snap off i suggest letting it start to purple at the tip) now this is a blade that will handle anything you have to throw at it.
Just my 2 cents.
Nice. My uncle makes knives similar but uses deer antlers and exotic woods for handles.. mostly boot knives. and he ,
makes leather sheaths as well. but nice instructable
Xthinker (author)  bcutnbords781 year ago
Hmmmm... I just so happen to have some deer antlers.
BUT, I already have a my next knife design, A tanto knife with a full tang and clear plastic grips I might use the bones for a pocket knife though.
Xthinker (author)  Xthinker1 year ago
I just remembered what the plastic is called! it's Lexan! I used to have some, but I lost it, so now I have to go to Ace to get some more :/
Tupulov1 year ago
The KISS principle! Love it. Well done instructable.
moochaka1 year ago
If you wanted to, you could probably drill a few holes and put some rivets or something like that in. I think it would give it a look similar to the "twin" series of J. A. Henckles knives. If that's your thing. Really cool though!
eyesee1 year ago
thanks
bmalek1 year ago
Neat! Next time keep one of the blade hooks on the top as a bottle opener!
sleeping1 year ago
nice work, thanks for posting it.
Xthinker (author)  sleeping1 year ago
Thanks!
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