This project can be done only with hand tools. I use power tools when ever it is possible and suitable for purpose.

Difficulty: easy
Time: 15 - 45 mins.

I have set of diamond hole chisels which I normally use with very thick leather. I have upcoming project with thinner leather so i looking for smoother stiching holes. I have in my tool bag one broken diamond chisel and I want to give this tool a new life as a flat hole chisel.

Safety equipment: eye and hearing protectors. Good gloves. Work clothes

Tools

- Bench vise

- Locking pliers

- Side cutter

- Diamond file(s)

- Angle grinder with cutting disc

- Bench grinder etc (optional)

- Needles

- Stitching pony

Materials

- Broken chisel

- Leather

- Waxed thread

Step 1: Preparations

Cut the prong(s) with side cutter and flatten the tip with file. Also file sides thinner.

Step 2: Make Prongs

I like big caps between stitiching holes. This chisel is 12 mm wide, but I make only 2 prongs 2 mm wide each. Cab between prongs is also 2 mm. You might think why I dont make more prongs with all that metal, but I am cutting with freehand so there´s more room for error and my projects are typically small so there´s no need.

- Attach the chisel firmly before you use power tool. Cut approx. 8 mm deep cut with angle grinder. Support your elbow on the table. (Your hand is more stable) If you dont´t have power tools this cut can be made with file.

- Shape edges with bench grinder or use file to achieve the desired prong size

- With diamond file(s) you can make final shapings and remove burr