Picture of Make a simple knife with pvc sheath
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I happened to come across a brand new circular sawblade but being that I do not own I circular I didnt have a use for it so i desided to make it into a simple knife.

I didnt want to go through the trouble of heat treating the knife but you can if you want to.
Remember that I didnt make this knife to be pretty, its just a little  beater knife that is fun to make.

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Step 1: What you need

Picture of What you need
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1. A sawblade or any useble piece of metal
2. pvc tube
3. little screws and bolts


1. a drill (not needed if you have a dremel)
2. an angle grinder
3. a pair of pliers
4. a file
5. sand paper
6. a work bench with a vise
7. dremel (optional)
8. an oven or heat gun
9. clamps
10. some foam material
11. 2 wooden blocks
12. water proof pen or sharpie
13. nail polish remover and toilet paper glasses
15. mug
16. hacksaw (you can use dremel instead)
17. creativity

Step 2: Designing the blade

Picture of designing the blade
Before you can start cutting out your blade you need to make a blade design. Take your time with this stap and remember that the knife needs to be strong enough , be comfortable and fit your tasks.

I used  a waterproof pen to draw  my design and the nailpolish remover to remove any mistakes.
You can also use features that are already there like the hole in the middle of the saw and the teeth.

Step 3: Cutting out the blade

Picture of cutting out the blade
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Now the real work starts.

remember to always use your safety glasses when cutting metal!!

Start by securing the metal in the vise or workbench and start scoring the metal.
Do not cut the metal cause you  run the risk that the grinder will get stuck in the metal.
You should try to score straight lines to make the next part easier
After scoring the metal about half-way put the metal straight into the vise and bent it back and forewards till it snaps. If it doesnt bend easily try scoring it further.

The idea is good, but the problem is, because you are using a circular saw blade that has carbide teeth, it is very likely that the rest of the steel is low carbon content, making it rather poor for knife making. If you want to make a knife that will hold a good edge, not only do you need better steel, but you need to properly heat treat it unless you are careful to cut it out and do all sharpening and shaping with it still hardened, without heating it too much, which is very difficult. Like I said, the idea is there, but a better understanding of knives and steel would be what you need to make this a really good instructable.
Agreed! It is a good start if you want to make another using the same techniques as you used here good to flea markets where they sell older circular saw baldes... Older blades have better quality carbon steel!!!

You can still make a knife using the metal removing/grinding w/out forging or heat treating, you just have to careful not to over heat the blade. If while gringing you starte to see colors pop up on the steel itself, this means you have over heated the blade. Do not throw out the blade just get a good book on steel heat treating and give that a try or what until you are deady to do so...!!!

If you quench the blade often while grinding you should avoid over heating the blade and can make a good quality steel blade by just grinding. Many knife makes make quality blade by just grinding a steel blank. Good luck with the next project!!!!
triumphman3 years ago
Nice job, enjoy your knife and sheath, it is cool, don't worry about the purists who
" must" have a special edge! That knife will work fine. After all, you are not a professional mercenary!
pietzeekoe (author)  triumphman3 years ago
Thanks fo the kind words :)
Arbitror3 years ago
The handle looks identical to a falcons head!
mac9694 years ago
very nice about using pvc to made the sheath, i am think about use pvc to made a rifle mag holster
NutandBolt4 years ago
Nice ible , I needed sawblade for my circular saw yesterday my blade tungsten carbide tips is breaking up after long use and abuse . There is no justice in this world..LOL
pie R []ed4 years ago
Be careful heating PVC. It releases toxic fumes. DO NOT inhale them. Use a respirator and ventilation if you must. If the fumes or PVC residue are still in the oven I wouldn't use it for cooking food.
pietzeekoe (author)  pie R []ed4 years ago
I put some tin foil in the oven before heating the pvc and i only heated it so that is become a little floppy. I didnt smell any fumes in the oven afterward so I think it wasnt hot enough for it to release any. But i could be wrong, I was in a ventilated area though.
seltzer104 years ago
nice ible and id like to give a tip if you are worried about heat treating exc. remember always quench your blade when using a angle or wheel grinder because it can heat the blade edge by friction where it can aneal it.
pietzeekoe (author)  seltzer104 years ago
Thanks for the tip and ill try that the next time :)
Where's the handle it should have some wood on there.
pietzeekoe (author)  the_burrito_master4 years ago
I accualy had the knife wraped with some bike innertube protective rubber. But you can attach some wood slabs to the knife by glueing them on with some epoxy and then shaping them.
Would it be possible to make the sheath from something like Plexiglas or sheet PVC?
You can buy PVC sheet at many online suppliers. Just seems like it would be easier than flattening PVC pipe.
pietzeekoe (author)  Bobthemonkey4 years ago
Yeah sheet pvc is accualy a lot better to work with, and plexiglas may give a cool effect. This was the first pvc sheath i made so i just tried using a pvc pipe.
Kydex is the plastic that most sheath makers use but its expensive compared to pvc and I dont have the tools to work with it the best material for the job.