Knife From Sawzall Blade
by graydog111 in Workshop > Metalworking
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Knife From Sawzall Blade
![IMG_0970.JPG](/proxy/?url=https://content.instructables.com/F8C/RG3G/IWWFK3UA/F8CRG3GIWWFK3UA.jpg&filename=IMG_0970.JPG)
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I've made a few knives in recent years and had wanted to make one from a saw blade. Since I'm almost 81, I cannot get to my shop as often I once did. Here is a simple little knife I made recently that I like a lot.
THE SAW BLADE
![IMG_0948.JPG](/proxy/?url=https://content.instructables.com/FDH/SD3J/IWWFK3N7/FDHSD3JIWWFK3N7.jpg&filename=IMG_0948.JPG)
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![IMG_2385.JPG](/proxy/?url=https://content.instructables.com/FRH/MFZ4/IWWFKZOR/FRHMFZ4IWWFKZOR.jpg&filename=IMG_2385.JPG)
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![IMG_2388.JPG](/proxy/?url=https://content.instructables.com/FU8/35DV/IWWFKZT1/FU835DVIWWFKZT1.jpg&filename=IMG_2388.JPG)
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I started with this worn out Sawzall blade. I shaped it with a bench grinder, a high speed air disc grinder & a 4" wide bench mounted belt sander.
THE HANDLE
![58597586e02ad6cf15000960.jpeg](/proxy/?url=https://content.instructables.com/FZZ/QVP3/IWWFKS0U/FZZQVP3IWWFKS0U.jpg&filename=58597586e02ad6cf15000960.jpeg)
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![IMG_2382.jpg](/proxy/?url=https://content.instructables.com/FKH/P7EW/IWWFKP11/FKHP7EWIWWFKP11.jpg&filename=IMG_2382.jpg)
I had this deer antler left over from another handle I made from the crown. https://www.instructables.com/id/Turquoise-Insets-M...
I cut out a straight piece of the diameter I wanted for the handle. Measure 3 times, cut once.
ATTACHING HANDLE TO BLADE
![IMG_0950.JPG](/proxy/?url=https://content.instructables.com/FGM/RCKX/IWWFK3QB/FGMRCKXIWWFK3QB.jpg&filename=IMG_0950.JPG)
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![IMG_2389.JPG](/proxy/?url=https://content.instructables.com/FH1/GOXT/IWWFKZV4/FH1GOXTIWWFKZV4.jpg&filename=IMG_2389.JPG)
I did very little to the antler except drill a hole with a 1/8" bit and enlarge it to accept the tang of the blade. I cemented it together with 2 part epoxy.
I polished it slightly with polishing wheel & medium compound. I didn't want it glossy; only semi glossy.
INLAID TURQUOISE ON END OF HANDLE
![IMG_2393.jpg](/proxy/?url=https://content.instructables.com/FCY/T043/IWWFLQFI/FCYT043IWWFLQFI.jpg&filename=IMG_2393.jpg)
![IMG_2392.jpg](/proxy/?url=https://content.instructables.com/FCN/VUDG/IWWFLQB7/FCNVUDGIWWFLQB7.jpg&filename=IMG_2392.jpg)
To jazz it up a little, I decided to add an inlay of turquoise to the handle. I did an Instructable on inlaying and it's too involved to cover here. If you want more info on inlaying go to:
THE FINISHED KNIFE
![IMG_0955.jpg](/proxy/?url=https://content.instructables.com/F2U/UOB3/IWWFK3TM/F2UUOB3IWWFK3TM.jpg&filename=IMG_0955.jpg)
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This turned out to be one of my favorites. it is small and easy to use. The handle has a slight downward shape and fits my hand nicely. The blade required no shaping except rounding the end and sharpening it. It had already been heat treated, I suppose. It's not as big as my huge Bowie made from car leaf spring but it's a nicer size. https://www.instructables.com/id/Bowie-Knife-2/ It's almost the same size as our set of steak knives
Try making one from a Sawzall blade. You'll enjoy making and using it or giving it as a Christmas gift as I am doing with this knife. I'm sure my grandson will appreciate it and save it as a family heirloom.