I happened to come across a brand new circular sawblade but being that I do not own I circular I didnt have a use for it so i desided to make it into a simple knife.
I didnt want to go through the trouble of heat treating the knife but you can if you want to.
Remember that I didnt make this knife to be pretty, its just a little beater knife that is fun to make.
Step 1: What You Need
1. A sawblade or any useble piece of metal
2. pvc tube
3. little screws and bolts
1. a drill (not needed if you have a dremel)
2. an angle grinder
3. a pair of pliers
4. a file
5. sand paper
6. a work bench with a vise
7. dremel (optional)
8. an oven or heat gun
10. some foam material
11. 2 wooden blocks
12. water proof pen or sharpie
13. nail polish remover and toilet paper
16. hacksaw (you can use dremel instead)
Step 2: Designing the Blade
Before you can start cutting out your blade you need to make a blade design. Take your time with this stap and remember that the knife needs to be strong enough , be comfortable and fit your tasks.
I used a waterproof pen to draw my design and the nailpolish remover to remove any mistakes.
You can also use features that are already there like the hole in the middle of the saw and the teeth.
Step 3: Cutting Out the Blade
Now the real work starts.
remember to always use your safety glasses when cutting metal!!
Start by securing the metal in the vise or workbench and start scoring the metal.
Do not cut the metal cause you run the risk that the grinder will get stuck in the metal.
You should try to score straight lines to make the next part easier
After scoring the metal about half-way put the metal straight into the vise and bent it back and forewards till it snaps. If it doesnt bend easily try scoring it further.
Step 4: Cleaning Up the Blade
After cutting out the blade the edges will be rough and sharp so look out.
To remove any burs first try making it smooth wth the angle grinder.
After that you can smooth out the edges even further with a file or dremel.
Step 5: Sharpening the Blade
I sharpened my blade with household items but you can use fancy sharpening stones and tools if you want to.
I started of by creating a rough cutting edge with the angle grinder, try to keep the edge as uniform as you can. after that i used a very improvised sharpening jig using a dremel vise and a metal bar I taped to a file handle. Though Im pretty sure your not ganna be able the exactly replicate my set up im sure you can make something to help you file an edge.
After filing the blade i taped some fine sandpaper to the file and redid it.
You can finish ofyour edge by gliding it over the rough exposed rim on the underside of a porcelian mug.
Step 6: The Sheath
To start making you sheath you should have pvc pipe that has a circumference that is atleast a inch more than you blades width to account for the screws. If your pipe's circumference is more than two times the width of your blade you can just heat the pipe , flatten it and stick the knife in, but make pipe is to small for that so I started of by cutting the pipe to length en curring it length-wise so i can fold it open. I put the peices into an oven at about 200°C (which is about 392°F) I also stuck some butter knifes into the slits to help me open up the pipes. After about a minute they start to get soft thats when you take them out en place them between two pieces of wood an clap those peices of wood together. Ones the pvc has cold down you but them back into he oven, make sure to put something on the pvc sheets like the knifes cause the pipes are ganna want to return to there old shape
Ones the pvc is soft again take them out of the oven and sandwich your knife between the pvc sheets and than sandwich the knife and the pvc between the foam and the blocks of wood and clap them till the pvc has cooled down again. The sandwiching and claping is kind of hard to do fast so prepaire to have to do it over again a few times till you get it right.
When your pvc has formed correctly drill holes through both parts and insert the screws (i used meccano screws).
My sheath turned out a bit ugly but it works
After this step you are pretty much done, but you can cordwrap and heat treat the knife if you want.
Have fun making your own knife and be safe.