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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.

Step 1: What You Need

materials

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

tools

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
14.safety glasses
15. mug
16. hacksaw (you can use dremel instead)
17. creativity

Step 2: 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

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.

Step 4: Cleaning Up the Blade

After cutting out the blade the edges will be rough and sharp so look out.
To remove any burs  first try making it smooth wth the angle grinder.
After that you can smooth out the edges even further with a file or dremel.


Step 5: Sharpening the Blade

I sharpened my blade with household items but you can use fancy sharpening stones and tools if you want to.

I started of by creating a rough cutting edge with the angle grinder, try to keep the edge as uniform as you can. after that i used a very improvised sharpening jig using a dremel vise and a metal bar I taped to a file handle. Though Im pretty sure your not ganna be able the exactly replicate my set up im sure you can make something to help you file an edge.
After filing the blade i taped some fine sandpaper to the file and redid it.
You can finish ofyour edge by  gliding it over the rough exposed rim on the underside of a porcelian mug.

Step 6: The Sheath

To start making you sheath you should have pvc pipe that has a circumference that is atleast a  inch more than you blades width to account for the screws. If your pipe's circumference is more than two times the width of your blade you can just heat the pipe , flatten it and stick the knife in, but make pipe is to small for that so I started of by cutting the pipe to length en curring it length-wise so i can fold it open. I put the peices into an oven at about 200°C (which is about 392°F) I also stuck some butter knifes into the slits to help me open up the pipes. After about a minute they start to get soft thats when you take them out en place them between two pieces of wood an clap those peices of wood together. Ones the pvc has cold down you but them back into he oven, make sure to put something on the pvc sheets like the knifes cause the pipes are ganna want to return to there old shape
Ones the pvc is soft again take them out of the oven and sandwich your knife between the pvc sheets and than sandwich the knife and the pvc between the foam and the blocks of wood and clap them till the pvc has cooled down again. The sandwiching and claping is kind of hard to do fast so prepaire to have to do it over again a few times till you get it right.
When your pvc has formed correctly drill holes through both parts and insert the screws (i used meccano screws).

My sheath turned out a bit ugly but it works

After this step you are pretty much done, but you can cordwrap and heat treat the knife if you want.

Have fun making your own knife and be safe.



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!!! <br> <br>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...!!! <br> <br>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!!!!
Nice job, enjoy your knife and sheath, it is cool, don't worry about the purists who<br>&quot; must&quot; have a special edge! That knife will work fine. After all, you are not a professional mercenary!
Thanks fo the kind words :)
The handle looks <em>identical</em> to a falcons head!
very nice about using pvc to made the sheath, i am think about use pvc to made a rifle mag holster
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
Be careful heating PVC. It releases toxic fumes. DO NOT&nbsp;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.<br />
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.<br />
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.
Thanks for the tip and ill try that the next time :)<br />
Where's the handle it should have some wood on there.<br />
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. <br />
Would it be possible to make the sheath from something like Plexiglas or sheet PVC? <br /> You can buy PVC sheet at many online suppliers. Just seems like it would be easier than flattening PVC pipe. <br />
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.<br /> 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.<br />

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