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Build a very strong keychain tool from a sawzall blade. Motivation: It is often a desperate move scratch at something with your keys. At best you wi...
Stuff: Sawzall Blade Center punch Grinder Dremel bit Drill Bench grinder
I wanted this to be about the size of a key - so I used my keys to determine the length. I used an old screwdriver to make scratches to mark the leng...
Use a center punch to start the hole. This will keep the bit from drifting around as you try to start the hole.
It took a long time to make a hole in the blade. I tried a regular drill bit with poor results. A blue grinder from a dremel kit worked well, the bi...
Test the hole. The hole here is a little too small to fit over both rings of the keychain. Measuring the keychain, the hole needs to be almost 0.2"...
I used a bench grinder to shape the saw. Removing several teeth makes the saw easier to hold.
To clean up the sides of the blade, use a fine grit wheel and a light touch.
Cut the blade to length on the square corner of the coarse wheel.
The sawzall blade cuts on the pull, so the key chain and keys can be used as the handle.
The fat end of the blade can be made into a second tool. This part already has a good size hole.
Shape on the coarse wheel and polish on fine. I tried to give the back of the blade a curve. Also ground off several teeth to make a little handle.
Here are the final pieces.
This one is pretty beefy.
I've changed the shape to make this a more practical hand tool. As a saw it just ripps stuff, this is more like a small knife or x-acto blade. It is...
Here are some more images of the saw in action. It is tough enought to screw in a screw, cut a tire, mangle rusty car metal.
The saw is good, but it does more ripping than cutting. There is also a spot that digs into my finger.
Here are some dremel tools that are able to grind the tough metal.
A bunch of the teeth have to go, in order to form a blade. The rough cutting is done on the grinding wheel.
The inner curve was hard to get right. I put the dremel grinder in a drill press and held the knife in my fingers.
The blade is only angled on one side (like a chisel). The back is flat. This allows you to sharpen the knife be pressing the flat side against a fla...
I have some fine stones with curved edges. I have these for sharpening curved wood lathe chisels (gouges). They need honing oil and can produce a ve...
I got a decent polish by rubbing the knife on a piece of wood covered in a fine rubbing compound (for a car). At this point the tool is tiny and shar...
Be sure to keep your keys and touch screen phone in different pockets!
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Posted:Jul 12, 2012
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