Introduction: Saw Knife and Leather Sheath

Picture of Saw Knife and Leather Sheath

Hey!

Once again I had an inspiration to make a new knife, but this time I was lucky enough to have a used saw blade, so I made the knife from it!

Tools:

  • Angle grinder
  • Saw
  • Bench grinder
  • Sandpaper
  • Hammer
  • Pliers
  • Oven

Materials:

  • Saw blade
  • Epoxy glue
  • Wood for knife handle (I used oak)
  • Charcoal
  • Nails
  • Vegetable oil (I used canola oil)

Step 1: The Blade

Picture of The Blade

I started with drawing the outlines of the knife on the saw blade. Then I used the angle grinder to cut the blade out.

After that I sharpened the blade. But you really shouldn't do that before hardening, because it makes it easier for the blade to twist. This blade did twist a little, but that's okay, it can't be seen from distance :)

Step 2: Hardening and Tempering

Picture of Hardening and Tempering

For the fire I used my grill. I fired up the charcoal and used a fan to heat them up even more.

I put the blade in there, and after a couple of minutes the blade was glowing red. I immersed it into the oil and after that I put it into the oven for 1 hour at 250°C (~482℉). However, it was not enough, I should have held it in the oven for a longer period, because later, while working with the blade, a piece from the tip broke off, it was too brittle.

Step 3: The Handle

Picture of The Handle

As I didn't have drill bits that are strong enough to go through steel, I used a different method. Instead of drilling, using the angle grinder I cut out a line in the handle, for the rivets.

After that, I marked the handle on a piece of oak, and cut out both pieces of the handle. I used nails as rivets.

Them I glued everything together and cut off the spare material.

Step 4: The Handle II

Picture of The Handle II

For the shaping of the handle I used the angle grinder and sandpaper.

When the most of the spare material was taken off, I started using sandpaper.

Then I put some wood stain on the handle, and used my special polish (bees wax mixed with linseed oil) on the handle.

I didn't like the handle very much, so I decided to carve some lines in it. And to make it even more beautiful, I made the both sides of carvings in different colors.

Step 5: The Sheath

Picture of The Sheath

I started with cutting out rough template, and the cutting it out of the leather.

Then I punched out holes for the rivets and holes for sewing, and when that was done, I connected and sewed everything together.

When the sheath was finished, I decided to burn something into the leather. A tree. It didn't turn out so well, but it definitely gives some character to the knife.

Step 6: The Knife

Picture of The Knife

It turned out really good. It looks nice, remains sharp for quite a while, and feels really good in hand.

This is not an easy project but if you have the right tools, it's something that, when finished, will make you proud!

You can check out my Facebook page HERE.

Comments

Gamge (author)2017-03-01

Love the knife!

Im a Blacksmith myself and I love how you use whatever you have on hand to make a great looking product! Keep up the good work man!

Xexos (author)2016-10-15

If you are having trouble drilling through steel, try using a carbide tipped masonry bit. They can make around 5-10 holes in 1/4" normalized tool steel before needing replaced (in my experience), and they only cost a couple bucks. Make sure to drill the hole BEFORE heat treat, it's almost impossible to drill through hardened steel with any kind of drill bit. When drilling, put a couple drops of 3 in 1 oil around the area that you are drilling, this helps lubricate the surface and keep the bit cool.

Hope this helps, keep up the good work!

Bluefang37 (author)2016-09-27

Yes I've never made one before thank you

Bluefang37 (author)2016-09-25

Here it is

ElmarsM (author)Bluefang372016-09-26

Nice! Is this your first knife? It looks quite well made!

Bluefang37 (author)2016-09-25

I am making a sheath

Bluefang37 (author)2016-09-25

I made it

Bluefang37 (author)2016-09-19

Also how do you burn the design into the leather

ElmarsM (author)Bluefang372016-09-22

I use a pyrography pen identical to one in the picture!

Bluefang37 (author)2016-09-19

Awesome. I was wondering if you could make a project ft someone who has never made a knife that is. Anyway awesome job

ElmarsM (author)Bluefang372016-09-19

I am planning to make another knife, might as well make it into another instructable :)

HollyMann (author)2016-09-14

wow wow wow...I always wondered what to do with the old blades! I am amazed.

ElmarsM (author)HollyMann2016-09-19

Thanks!

Rizwan Azami (author)2016-09-12

Impressive innovations (like use of the angle grinder because you didn't have the bits / drill press) and excellent presentation, thank you for the post.

ElmarsM (author)Rizwan Azami2016-09-19

Thank you!

mmaiden54 (author)2016-09-06

You did an awesome job and the pitted blade really gives it character. Is a Dremel cutoff or air tool cutoff what you used AND did you care about the heat from the cutoff given you tempered it yourself?

ElmarsM (author)mmaiden542016-09-19

Thank you!

I used an angle grinder, and there is no need to care about the heat if you're going to heat treat the blade!

Bluefang37 (author)2016-09-19

For not ft

deluges (author)2016-09-05

I'm always impressed by your work man :)

ElmarsM (author)deluges2016-09-05

Thanks! :)

RolandM21 (author)2016-09-04

;) + 1 on peut faire pleins de truc avec ça . Moi car j' avais besoin d' outils à sculpter ... Quand on voit le prix des ciseaux a sculpter

tachedub (author)2016-09-03

I am looking at the cutoff portion with the saw teeth in place and can envision another knife from it. Nice use of alternative techniques in your construction.

ElmarsM (author)tachedub2016-09-04

Thank you! I am sure that there is enough of the saw blade to make plenty of new knives!

todddanielsmith (author)2016-09-03

Very very nice!!

Now I will be looking for saw blades at local garage sales. How long should the knife blank be left in the oven after the initial heating and quenching in oil?

Thx for posting this.

ElmarsM (author)todddanielsmith2016-09-04

Thank you! You should keep it in the oven for 1.5-2h depending on what you will use the knife for.

Tempest Mage (author)2016-09-03

Nice, I'm definitely going to make my own knife much like this one

ElmarsM (author)Tempest Mage2016-09-03

And when you do, please post some pictures here, I would be glad to see the knife.

3366carlos (author)2016-09-02

supper awesome

ElmarsM (author)3366carlos2016-09-03

Thanks!

The Rambler (author)2016-09-02

That is a gorgeous knife. I love the detail on the pommel. Fantastic job!

ElmarsM (author)The Rambler2016-09-03

Thanks!

alatpijat (author)2016-09-03

http://kask.us/iixFi

Essyx42 (author)2016-09-02

I don't have a lot of tools, but i have almost evrything you used. No excuses, i have to make a knife using your instructable. Good work! I like the rustic look of your knife. Thanks for sharing.

ElmarsM (author)Essyx422016-09-02

Thank you! And when you do make it, post some pictures here, I would love to see it!

SvetlinZ (author)2016-09-01

Good work

ElmarsM (author)SvetlinZ2016-09-01

Thanks!

altomic (author)2016-09-01

excellent.

ElmarsM (author)altomic2016-09-01

Thanks!

frabfrt (author)2016-09-01

Its magnificent :)

ElmarsM (author)frabfrt2016-09-01

Thank you! :)

crickleymal (author)2016-09-01

How do you rivet the handle?

ElmarsM (author)crickleymal2016-09-01

I drilled holes in the handle a bit smaller than the nails, and then punched the nails into the handle.

tury70 (author)2016-08-31

I love your instructable !! I also want to make a knife but need to get the tools together first...

ElmarsM (author)tury702016-09-01

Thanks! The tools are totally worth it, one way or another!

About This Instructable

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Bio: I'm a simple guy from a simple country called Latvia. I enjoy making useful (and sometimes not so useful) stuff to make people around ... More »
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