Instructables

New Saw blade for sawzall (Updated)

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I was needing a way to cut a 0.75" channel in some plywood. The usual way of cutting two lines and then chiseling out the middle... I don't like. 
So I thought and thought and eventually came up with this....

The idea is a dado blade for a sawzall.

So I got three used sawzall blades (the one in the saw is a thicker metal cutting blade. the others are the big toothed ones for aggressive wood cutting)  and cut one into 1.5" chunks. Then very carefully lined the two outside blades up so they are 0.75" apart. and welded the cut pieces into place. 

the teeth are all going in the same direction and the blade chunks in the middle will clean out what the side blades can't. 

And it works!!! I was so amazed. 

First tweek: the two side blades need to hit the wood first then the middle pieces come next. I have them all working on the same level at the same time. This way the sides will guide the middle in and it won't move side to side as much. 
Tex Arcana5 months ago
AWESOME HACK!!! Now to go make one before some corporation steals it and sues everyone
Robot Lover7 months ago
This is a great idea! This could also be used as a hand file. It might even be good for shaping foam.
pclplante1 year ago
I'd get a patent quick before someone steals the idea.
no joke, i can imagine seeing this sucker in the hardware store for sale at 15$ a blade.
TOOK THE VERY WORDS OUT OF MY MOUTH!
you should grab some video of this hack-tool you have established, I would love to see how quickly it removes material.
bigtreehouse (author)  audreyobscura1 year ago
Okay... just for you... In HD!
rusty901 year ago
Neat quickn'dirty hack! My guess is that the same could be done with pop-rivets, just bending the center blade into a zigzag, drill at the vertices and where they contact the sides, then rivet. Additional bonus, the temper of the blades will be less impacted by the drilling and bending than by cutting and welding, thus less likely to shatter.
Good point about the temper, but have you ever tried drilling one of those blades? Aint gonna happen! Perhaps you could re temper the whole thing once it's done.
RangerJ1 year ago
I like it. I'm sure I will be making one the first time I need to do some dadoing.
rimar20001 year ago
Very clever hack!