Also, I have to give a shout out to this video for teaching me how to do this.
Step 1: Materials
I had to go out and get a small butane torch. There were a few at the hardware store, but the one I liked I found at a restaurant supply store labeled as a creme brulee torch.
- Two needle nose pliers
- Wire cutter (can be on the pliers)
- Coping or jewelry saw blades, wire, or whatever you'd like for your tool
- Brass tubing, old paint brushes or metal knitting needles
- Small butane torch
- Super glue
Step 2: Make Your Handles
Knitting needle: I assumed it was a hollow needle because of the weight and the sound it made when I tapped it. Then, I did the same as with the brass tube, but used a pliers for the small end to snap it off. There was a little bit of liquid inside the needle, but I tapped it out. It wasn't flammable, so I felt ok about moving forward.
Paint brush: I cut down the old bristles and then burned out the rest with a lighter. I cleaned out the burned interior with a pin. There were still bristles about 1/4 inch deeper inside that I couldn't get to, but it ended up that the jewelry blade fit more snuggly with the bristles still in there.
Step 3: Bend the Blades
Coping saw blade: Holding the the blade in a gentle arc with the pliers, I quickly moved it up and down at the end of the blue flame until it started to bend. It was kind of tricky to get a nice gentle loop because as soon as it got hot, it would bend into a point. That made the flat shape a bit easier, but that also was more bends. At the spot where I wanted it to go into the handle, I bent both sides again so it was a Y shape.
Jewelry blades: Dang these things like to break. While I almost didn't need the torch for the coping saw blades, these buggers can't take much torque at all. I ended up not arcing the blade at all before putting it in the heat and then when it hit temp, it would bend immediately. I also ran into an issue of getting it too hot and the teeth of the saw started to go flat.
Step 4: Attach the Blade to the Handle
I put the blade carefully into the end of the handle and clamped it down with a pliers. The blades moved around a bit on me, but I was able to wiggle them back into place. I used a dab of superglue to lock them in while I mixed up my epoxy.