Introduction: Steel Pumpkin Saw

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This Idea evolved from a sad experience many Halloweens ago where my flimsy grocery store bought tool failed halfway through carving a jack-o-lantern, leaving me no alternative but to use a steak knife. That was unacceptable. I needed a more sturdy tool. One that would handle curved cuts without breaking.
   In my opinion this little saw performed remarkably, and at the right as free.

This instructable assumes that you have access to a welder.

Step 1: Tools & Materiels Required

Picture of Tools & Materiels Required

Tape measure.
A welder.
An angle grinder with cutoff wheel, and a sanding disk.
3/8" steel rod.
1 used or new wood cutting jigsaw blade.
Bench Vise or C-clamp.

Step 2: Cut Your Stock

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Clamp your rod into the vise or onto a table and cut your 3/8" rod to 4" using the cutoff wheel.
While it is still clamped, cut a notch 1" deep in the end as shown.

Step 3: Fit Together

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Put the base of the saw blade into the notch.

Step 4: Weld

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Lay a bead in the top and bottom of the notch to secure the blade.

If you do not have access to a welder, you could probably epoxy it in place. I like PC-7 for such things, although I have not tried it for this project.

Step 5: Grind Smooth

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Change the wheel on your grinder to the sanding disk, and smooth the bead as even as you can.


l8nite (author)2009-12-01

 I used to have a model builder friend who did basically the same thing only using wood dowels for the handles, a bit of epoxy and a sewing thimble as a ferrule. Nice "ible"

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