I made a new shop knife out of a old Sawzall blade. First I stripped the paint with a belt sander, then I drew out the shape I wanted. Next I used a 1" belt sander to shape the knife blank. Then I annealed the handle part so I could drill holes for the brass pins. To anneal the steel I heated it to a cherry red hot and let it slowly cool down. Keep the heat on the handle end, you want the blade end to stay as is.

The beginning of the blade.





Next I polished the blade by sanding with sandpaper, 150 grit through 600 grit. This is a shop knife, the 600 grit s high enough.





Cut the scales/handles to the size I wanted. This was a scrap of leopard wood.



I epoxied one side to the knife blank.

After the epoxy has dried overnight I drill out the hole for the brass pin and trim the scales/handle to the basic shape I am looking for.



I then epoxy the other side on, and drill out the brass pin holes using the first side as a guide. And epoxy the pins in place.



After the epoxy has dried overnight I then start shaping the handle. I use either a 1" or 2" belt sander. But this can be done using a Dremel with a drum sander.



Now I finish sanding by hand, starting with 150 grit, I sand until I have the shape I want. Using the 150 grit to get the nice rounded corners is easier than trying to start at 220 or higher. Once I get the shape I want all smoothed out I then finish sanding up to 600 grit.



First coat of oil finish on the handle.



Maybe sometime in the future I will try to make a sheath for it, but as a shop knife, it isn't needed.

Well that was cool to see! The pics are great. With those instructions I think I could pull it off and may give something similar a try.

Looks good.

And just like that, you have a knife. Very cool.

So just an regular ole blade hu well that's cool as heck man I may have to try that

Any questions, just ask. I am no expert, but I have made a few of these over the years. The shape can be done with a Dremel, just tales longer. Never forget to anneal the handle end or you will ruin a few drill bits and never get a hole drilled. Heat it hot, cherry red, and allow to cool slowly.

Pretty cool DC, nicely done

Looks great DC.

nicely done!

Well done.

Nice post

I gotta try that.

Great post!

x2

Looking good,Marvin! I've got an old file and a small antler shed that is fixing to be made into a small EDC knife for a good friend.

That is great.

Nice knife. Was the sawzall blade a thin metal cutting blade or a thick wood cutting blade? Where do you get pins and what type of epoxy? I would like to make one.

I think it was a metal cutting blade, but I have also made them out of wood cutting blades. You can get the brass pins at Hobby Lobby, K&S Engineering brass rods in the model airplane section or you can use brass welding rods. I have also used wire clothes hanger wire for the pens, they will work. The epoxy came from Harbor Freight, I just happened to be there and picked it up there, any epoxy will work.

Thanks Dogcatcher.

If someone wants to make some easy Christmas gifts this could be a $10 gift. Buy several of these blanks.
http://www.premiumknifesupply.com/servlet/Categories



Not the best knife blank, but decent quality, and it would be a good learning experience.

I have it book marked. Thanks for sharing.

Nice job!!

I have bought the blanks to make knifes too, the fun part for me was the handles. When I was a young High schooler, on of the old guys in the shop would make them from auto leaf springs, he was a true artist.

wow....I might just have to try this. This could be the thing to get me going into the garage and really start learning some handy stuff...

I've already found 3 blades I like and looking at scales on that website too.....

I bet there are a record number of knives given as gifts this year and next year. Such a cool idea. I can't wait to get started! Nice job!