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Step 2: Designing the Blade

Starting with a 'sawzall" blade, clean the surface and design the basic shape of the blade and the hidden tang. Try not to use any portion of the actual sawing area. This is a rough design to use on the grinding wheel. I used a piece of soapstone to mark the metal.

Plan to use the hole at the rear of the blade to hold a pin to anchor the blade in place. Next, using a model of the handle, determine the location of the second hole to anchor the blade to the handle. Use an awl or nail to mark the hole location on the metal. Sawzall blades are very hard and nearly impossible to drill, so we will punch a hole rather than drilling a hole. Place the metal over a hole in a steel plate or block of wood. Using an 1/8" punch, tap a hole in the metal.

Now take the blade to a grinding wheel and remove excess material to create the basic outline of the blade and tang. Use water to keep the blade cool as you shape the metal.

<p>Nice knife, I made these a while back and they have been put up in a box. When I saw yours it reminded me of the knives I made. They fit my hand very well and cut great. I mainly use them for rough cut and I made a few other knives for finishing and detailing. You did a great job, it looks nice. Thank you for showing us!</p><p>Joey</p>
<p>I made this today. It didn't go so well. Mostly due to my lack of skill.<br>Gonna try again tomorrow. Lessons learned and all that.</p>
<p>Sweetness!</p>
<p>This looks great, I love the handle design!</p>
<p>A local woodworking group created the design. It is easy to duplicate and comfortable in the hand.</p>
I like it!! Voted
<p>Thanks</p>

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