I like to carry tools with me but a saw for emergency or neccesity was always too bulky. Recently someone locked their cable bike lock through my lock and I wished I had a saw blade to just go through it. I had a handle that fit SAWZALL blades but it was just too big. I liked the size of the Bosch t shank blades. They fit easily into everything I carried but I couldn't find a way to get a handle on them. I searched and searched. So, I decided to experiment with making something myself. I bought a drafting program on the app store, measured the t shank blade and drew it out in 3D. Had it printed online (shapeways). It was much easier then I thought and, to my suprise, it worked.
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Step 1: Measure the Shank
I used a simple pair of calipers to make all the measurements. I really tried to be both accurate and precise, but frankly, the cheap calipers worked fine. I think if you are close enough, it will work well enough. Also, I was prepared to do material removal/ fine tuning just in case.
Step 2: Arbor Method
I wanted an arbor that I could keep small and incorporate into my EDC tool roll. Making this small two part square allows me to really keep everything small. You can pair this with either a vice grip or some other kind of C clamp. I tried holding it with a leatherman but it just didn't work. The jaws didn't open enough and not enough grip.
Step 3: Printing
I submitted the files to shapeways and had them printed in plastic. They really seem to be sturdy enough. If anyoen wants the files, I will be happy to let you use them. Just an FYI, depeding on the blade, you may have to remove some material at the opening. I measured a metal blade, then when I tried to put a wood blade in, the teeth stuck out and curved so I had to remove a mm or so of material with fine grit sandpaper. I didn't have to make any other adjustments.
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