This is one my entries for both the pocket sized and epilog contests. Please vote! I've been trying to get that Leatherman for quite a while!
When I saw some ultra-cheapo "Light My Fire" spoknorks(pronounced spo-nork, meaning a spoon, knife, and fork) at the store, I decided to make my own high-quality, metal version.
I bought two sets of silverware: one set of two 8" forks, and one set of two 6.5" spoons ($4 total). I used an angle grinder to cut the handles to length and trim the fork's prongs to match the bowl of the spoon. I rounded the cut ends with my bench grinder. Next, I smoothed the tines with a dremel and gently sharpened one of the prongs (be sure to blunt the edge slightly; you really don't want to cut your mouth open). I taped the handles together, one on top of the other. I used a drill press to drill two holes (1/8" diameter), about 3/4" apart, in the stacked handles. Then I cut two lengths of brass pin slightly larger in diameter than the holes, smeared them with epoxy, pushed the pins into the fork's holes, and hammered the spoon onto the fork. Once the epoxy was dry, I used the dremel (again! I use that thing a lot) and ground the pins down so they were flush with the surface. Finally, I pulled the tape off and ran over the joined handles and pins with some 800 grit sandpaper.
There now, that wasn't so hard--or, more importantly, expensive! I'd say 5-10 bucks, max. If you want a pro look, get some 'ware with handles that are uniform width along their length, and put more pins in.
I repeat, PLEASE VOTE! I REALLLLLLLLY WANT THAT LEATHERMAN!
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