How to Make a Saw Blade From Knives.

This is my first instructable. I have a couple more in mind. Hopefully you find this useful

Step 1: Reexamine Your Life.

Really. What has lead you to this point? You are about to look into making a saw blade from a bunch of knives. What kind of loony does that? Well there is me of course. Good luck!

Step 2: Decide on the Knives You Will Use.

Ok, you've come this far, let's get on with it! I searched amazon for throwing knives to use in my project. I wanted uniform steel knives without a handle so they would lay flat on the wood. They also needed holes that could be used in at least 2 places to attach the blades to the wood. I selected a set of 6 that met my criteria and I bought 2 sets. The set was cheap (~$12 each) and fit my pitiful budget.

Step 3: Selecting and Preparing the Wood.

I chose a piece of fairly flat and straight 1x12 pine. I cut a squarish piece from the board without knots. I affixed a printed out version of the template above to the board using spray adhesive. The print was about an 8" circle. I did a test fit of the knives to see how wide to make the board. I left about 1/2" from where I planned on the outer screw and the edge of the board. I then cut the board on my bandsaw and drilled a hole in the center to fit my bench grinder. I attached the board to my bench grinder and sanded the edges with the grinder running to get a satisfactory circle.

Step 4: Affix the Knives to the Board.

Now that the board is perfectly roundish, we can attach the knives. Line up the holes in a knife with the radiant lines from the template. Choose an identifying feature that lines up with one or more of the circles. Using a screw (I used 1/2" screws) attach the hole closest to the center first. Since the screws are small, I used a screwdriver rather than a drill to ensure there was no tear out. Ensure the outer hole is aligned as required and add the outer screw. Continue for the remaining knives.

Step 5: Attach the "saw Blade" to Your Bench Grinder..."enjoy"!

If you haven't already, remove a grinding wheel from one side of your bench grinder. Attach the blade to your grinder and try to come up with a safe way to use it.

My blade was super powerful, and intimidating. My assistants were reluctant to assist with a full demonstration and we did an abbreviated demo instead. Please check my video, hopefully the full amount of danger came through.

Enjoy!