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Hi fellow Makers,

This summer I went on a 5 week camping trip to the Alps with some friends. We went rock climbing and mountaineering and had lots of fun. On this trip I found out that I forgot one very important tool: an axe. We really like to build camp fires and drink beer after a long day of climbing, but without an axe to cut firewood we had to spend a lot of time finding smaller tree branches we could brake by hand to make the fire.

So when I got home I had the idea of making a survival tomahawk inspired axe, that features a pocket knife style saw blade and most important, a bottle opener to open beers!

This Instructable will show you how you can make your own!

Step 1: Design

The design of this axe consists of 3 pieces:

Axe head: The shape of the head is inspired by a tomahawk, an axe originally used by Native Americans and European colonials. Feel free to change the shape however you like, maybe add some cool spikes or a hammer shape to the other end. The axe head will be pinned and glued to the handle.

Bottle opener: I originally wanted to use a rounded hole in the head as a bottle opener. A quick test showed me that drilling a hole in the blade with standard drill bits was not possible (it's hardened), so I changed it to a different type. You can see the difference in the picture, the new type is also known as a churchkey style opener.

Sawzall blade: I wanted to add a saw to the axe and I thought it would be cool to do it pocket knife style. The blade is stored in the handle and can swing open (there is a finger notch to grab the blade). The blade is sandwiched between the two handle scales. A metal piece is shaped so that the blade can swing open and locks it in the open or closed position.

Once I was happy with the design I checked if the pieces would fit inside the saw blade, they did! just barely :)

I have included a 1:1 PDF that you can print out, make sure the square measures 50 mm.

Step 2: Materials and Tools

This axe is made from an old saw blade and some hardwood I had lying around. I only had to buy a sawzall blade for this project, so it cost me around 5 euro/dollar. The steel of the blade is already hardened so you don't need to harden it when it's done. I know this might not be the very best steel, but it's what I had and it's free!

Materials:

  • Old circular saw blade
  • Piece of hardwood (roughly 50x40x300 mm)
  • Epoxy
  • Large nails for the pins
  • Sawzall blade (I used a 200 mm blade)
  • Bolt, nut and washer

Tools:

Step 3: Make Sparks!

I transferred the shape of the axe head and lower part onto the saw blade and cut it out using an angle grinder with a thin cut off disk. I then used the disk sander, angle grinder and files to finish the pieces. The exact shape of the lower part of the handle, can be tweaked later.

Step 4: Cutting Out the Handles

You can glue on the template and cut out the two handle pieces. I just used my CNC to cut them out (you can read about it here)!

Step 5: Drill Hardened Steel?

I don't have any carbide metal cutting drill bits, so I wasn't sure how I would drill the holes in the hardened steel of the axe head. I came across a video by John Heisz that showed that you can use sharpened masonry bits to drill in hardened steel. So that's what I did and it worked quite well!

Step 6: Adding a Bottle Opener!

This might just be the most important feature of this axe! Whenever I am camping with friends we usually drink a couple beers at the campfire. Opening beers with rocks or tree branches is not super easy, so I figured it would be a good idea to add a bottle opener to the axe head. I traced the shape of a real bottle opener on the axe head and cut it out. It works like a charm :)!

Step 7: Drill and Dryfit

Next I drilled the holes in the handle and tested if everything worked. The lower metal piece should act as a spring to keep the saw blade in place. If it's too stiff you can make the lower part a bit thinner (see pictures). First I used the metal pieces as a template to drill the holes, then I clamped the two handle pieces together and drilled all the way through. This way all the holes line up perfectly.

I used some bolts to do a dry assembly of the axe. Now you can test if the saw blade mechanism works and if all the pieces fit.

Step 8: Sharpening the Head

After tracing the bevel on the axe head, I used the angle grinder with a sanding disk to roughen in the bevel. Then I used a file and the disk sander (use water to keep the blade cool) to finish it. I did the final sharpening with a honing wheel on the bench grinder.

I'm not an expert in axe sharpening, so I would love to hear some good tips (correct bevel angle etc.)!

The axe will mainly be used to split wood into smaller pieces, so I did a quick test to see if it would work (see picture).

Step 9: Glueing and Pinning

The axe is glued together with two part epoxy and pinned with 5mm steel pins (I used some large nails). Before you glue everything together, don't forget to add some finger notches to the wooden handle pieces. It's a good idea to roughen up the surface of the metal pieces with a file, so the epoxy bonds better. Only apply glue to the head and upper part of the metal spring piece. The lower part needs to be able to move and act as spring.

Step 10: Shaping the Handle

Now that the pieces are glued together, it's time to give the handle a comfortable shape. I used a rasp, files and sandpaper. A strip of sandpaper works well to sand the edges.

Step 11: Finish and Conclusion

I finished the project by applying some oil and installing the sawzall blade. The axe only weighs 300 grams, so it's easy to take it with you in your pack. I would like to make a leather sheath for the head in the future.

I haven't had a chance to go camping again, but I did a quick test in a nearby forest. The saw works well to cut tree branches into smaller pieces and the axe was used for making kindling! The bottle opener works too, so that makes for a successful project :).

Benne is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means to earn advertising fees by advertising and linking to amazon(.com, .co.uk, .ca etc) and any other website that may be affiliated with Amazon Service LLC Associates Program.

I hoped you enjoyed reading this Instructable and would love to hear your ideas and suggestions about this project in the comments. If you you have any questions feel free to ask!

<p>really cool</p>
amazing! I'm gonna make this! thanks for the idea!
<p>Hi.</p><p>I really enjoyed this guide so i made one myself :-)</p><p>Without the saw, just plain handle for now. The next time i hope to use a round steel saw blade so it will be thicker and stronger. </p>
<p>Nice project! When I want to drill hardened steel I always &quot;dequench&quot; it by heating it to red hot with my torch</p>
<p>Well done though I would recommend a different brand of beer.</p><p>Leffe is a well known commercial (and industrial) beer that contains a lot of sugar and no specific taste. Go for small traditional breweries. The taste makes it worthfull carring to the top.</p>
<p>:-) Cheers! :-)</p>
Aaaaand Done! Well almost, still gotta sharpen the axe and polish it up a bit. Awesome ible!
<p>Fantastic, well done! Thank you for posting the pictures, it's awesome to see the finished project.</p>
<p>just started on this! Turns out my saw blade is smaller than the one you used (mine was 7.5 inches) so I'm making a scaled down version, perfect for my daughter to bring camping (so maybe I'll leave out the bottle opener). Pics of the progress so far...done using a Dremel with a cut off disc, well, 2 and a half of them!</p>
Awesome, great job so far!
<p>So good &amp; Wonderful idea </p>
<p>quite Well thought out WELLDone sir !</p>
<p>ha - love this. Using tools you've made for a specific need is so satisfying - good stuff.</p>
<p>Nice 'ible, it started my thinking... :)</p><p>Got some questions, thoughts:</p><p>1. What is the thickness of the circular saw blade?</p><p>2. What is the thickness of the sawzall blade?</p><p>3. How did you fixed the pins in their places? Simply gluing them?</p><p>4. What force is needed to open/close the blade?</p><p>5. I think the pin at the end of the handle - which the sawzall blade revolves around - is the weakest spot, maybe that should be made from some hardened steel, or have some bearing/bushing. The hardened steel of the sawzall blade is pressed to the pin, so it will eat itself trough it really fast.</p><p>6. Doesn't the sawzall blade &quot;eat&quot; the inner edges of the handle when it gets closed? (this depends on the thickness difference between the two blades)</p><p>7. Finally could you post some video about opening/closing/using the axe/saw?</p>
<p>Wonderful idea &amp; great build. The finish is professional. Hats off.</p>
<p>That is a real purty axe! I'm making something similar with similar materials. Hopefully, it will turn out as nicely!</p>
Nice axe. Saw blades are not hardened steel though, they are typically mild steel or a low carbon alloy. If you are able to file 'hardened' steel its not hardened.
<p>Hi, thank you for the info. Depending on the type of saw blade you use, the steel is definitely hardened. Standard HSS blades (not carbide tipped) can be as hard as 64 HRC, the blade I used was carbide tipped and around 43 HRC. Not super hard but definitely 'hardened' (heat treated). Most files range from 40 - 65 HRC, so that's why I was able to file the steel a little bit (I mainly used the angle grinder). </p><p>We will see how well the edge holds up, but during the tests I did it stayed pretty sharp :). Do you know the best method to give the blade an extra heat treat? Heat with a torch and oil quench maybe?</p>
<p>I have heard of people using pine straw to introduce carbon into the blade. I cannot confirm if it works or not. if you go to midway usa's youtube channel he does a full thing on color case hardening. I would think you could find a comfortable mid ground with it.</p>
Water would probably be better, you wont likely crack that steel with it. The higher carbon steels will though.
<p>You can also use a propane torch to do it with steel this thin but I'm not sure if you will be able to temper it because you already put on the wood handle</p>
<p>Ideally if you can heat the axe (cutting edge) to red hot and then quench in oil, you want a slower quench than water would give to reorganize the carbon and just harden the outside edges while leaving the interior of the metal somewhat softer to withstand impacts so it won't shatter/crack. There are lots of youtube videos demonstrating the technique for this, some say to heat until the metal loses it's magnetic properties as judging the temp can be fairly difficult from colour alone.</p>
<p>This is a AWESOME IDEA!! A+++. but just an fyi saw blades that are carbide tipped are not hardened and will not harden. you need a carbide free blade if you want to have something that will hold an edge.</p>
<p>Hi thank you for your comment! I do not completely agree with you about the hardness of the blade, without knowing the exact metal used in the blade it's hard to say anything about it's properties. This video discusses hardening of different kind of blades and also shows that carbide tipped blades can be hardened: https://www.youtube.com/watch?v=rJAKOtlJB48 See also my comment below, I definitely agree that standard HSS blades (not carbide tipped) are probably better to use! I think it would be really interesting to do some hardness testing of different blades at my university, but this will probably have to wait for a couple of weeks. Thanks again and have a nice day!</p>
<p>I am not here to argue the point with you or rain on your nice article. I am just stating the facts. they use cheaper metal in carbide blades for this reason. this comes directly from Freud tools. it is simple, try to temper a blade then have it rockwell tested. that will give you your answer.</p>
<p>If you look at the sparks in the picture where he's cutting the blade out, you can see that they have little bursts at the ends which means it is high carbon steel and can be hardened </p>
<p>This is Awesome, now i have to make one.</p>
<p>This is really nice! Is there a point (ha!) to the spike opposite the blade, or is it for aesthetics, or balance? If not, you could probably get a larger head out of the saw blade if it had a flat back. And it would be even more out of your way while sawing. <br><br>You got my vote - and I'll put it on the list of projects I want to try. Thanks for posting!</p>
Awesome project! I took it up the same day I read your article. My angle grinder is making a mess of it though! Hopefully ill get it as nice as yours. I will use it to open a couple of Hertog Jan's though! ?
<p>Awesome man! Looking good so far, I used a sanding disk made for metal (step 8 picture 3) to smooth out all the curves of the metal pieces. Good luck with the rest of the build, would love to see how it turns out!</p>
I do have a homemade sandingdisk but I havent come around to make the 90 degree table in front of it. So I just rasped, filed and eventually sanded alot by hand. Came out pretty smooth. Waiting for my recipro sawblade to arrive. Gonna set back the build by a couple of days but I'll post pictures of the finished project! Also I'm thinking about making a bolt and nut for the recipro sawblade instead of a fixed nail so you would be able to swap the blade if needed.
<p>Awesome survival tool! I love the look and the bonus bottle opener! Good idea to use an old saw blade for steel. What kind of steel blade do you recommend?</p>
<p>A non carbide tipped circular saw blade (table saw or cold saw) is probably best. These blades are made from high carbon steel and are a bit harder than carbide tipped blades.</p>
<p>Pretty cool!</p><p>If you had a welder you could have welded the two parts together. That would make it alot stronger i think.</p>
<p>Yes definitely a good idea, sadly I don't have one. (I added this Instructable to the metal contest, so maybe if I'm lucky... :)!</p>
<p>it is a very cool idea</p>
<p>Nice repurpose of a saw blade.</p><p>Have you tried it on a piece of chert or flint as a fire starter? </p>
great hatchet, does it have good enough weight to really whack into a branch?
<p>Well it is pretty light, so the saw is mainly used for the heavy cutting of larger pieces and the hatchet for splitting smaller pieces into kindling. As a 'survival' axe it works very well, but if splitting large pieces of wood is the only thing you want to do, I would definitely make it larger and heavier.</p>
this is awesome looks verry good.
<p>Thanks!</p>
Nice Ible...thanks for sharing!
<p>No problem ;)! thanks</p>
<p>best instructable iv'e seen all year! </p>
<p>Haha, thank you for the kind words!</p>
<p>that's awsome !</p>
<p>Thanks :)!</p>
<p>Looks really great and useful.</p><p>Love that it is multi functional.</p><p style="margin-left: 20.0px;">Is the axe blade made of a circular blade sturdy enough though?</p><p style="margin-left: 20.0px;">You also have a good taste of beer :p</p>
<p>Beautiful! </p><p>I wanted to make something like this a long time ago, but right before I started building it, I thought it wouldn't be comfortable to saw with it. </p><p>It's obvious that you can saw wood with it, but what I mean is that making a folding saw (as a separate project) would have been easier, faster, and safer to use... What do you think? :)</p>
<p>Thanks, I wasn't sure about this either. As you can see in the final step, my hand fits around the handle nicely and can hook behind the head so to say. In this position you can saw very comfortably. Of course the main objective of this project was to combine 3 tools in to one :)!</p>

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