Step 1: Materials and Tools
Some sort of 2-Dimensional software that can read/write AutoCAD DXF files
A piece of metal, either sheet or flat bar, 36” long and 3” wide – I used titanium because I had access to it, and it has ideal properties for the final saw, but any 5000, 6000, or 7000 series aluminum between .080 and .125 inches thick will work pretty well too.
Scrap wood – 1/4-inch thick for the handle, you will need enough to fabricate the type of hand you want.
Some sort of fastener for holding the handle to the blade – I used two (2), 3/8-inch diameter by 1/2-inch long aluminum binding posts
Plasti-Dip – or some other sort of coating that will give a good grip through your gloves in cold, wet weather.
Sander – I used an angle grinder to sand both the wood on the handle, and add a finish to the titanium
Drill and bits for drilling holes for attaching the handle
Screwdriver –For attaching the handle
Wood Saw – I used a band saw, but any saw that can cut wood it fine
A few clamps
1 cheap disposable paintbrush
Now that we have a list of materials, we can start the build process of the saw.