Home made drawKnife from Old saw blade Build along

[globalmark]

Hi Guys
thought few people interested in How I make some of my Tools , for woodworking and Bow Building (being a engineer, cabinet maker - i have made a few basic tools over the years) - not a blacksmith but can use old steel and rework them ..
this is a small Drawknife i made this week - as the 2 i have already are a bit big for doing refined bow work..

Old saw blade found in the hedgerow - broken i should think maybe 80-100 years old and is definitely Hard steel - I didn't photo everything But have most steps here so if someone wants to make one they probably can -


1. Saw blade as found
2. Made template from thin MDF - to help scribe around
- I actually Cleaned Blade with wire brush on drill and sanding disk on angle grinder before next stage - forgot pic but you can see blade cleaner
3. Used a 4.5" angle grinder with thin metal cutting disc - and scribed/ cut small section then moved and did on other place - was SUPER careful not to overheat the blade - i stopped ALOT drop in water - also just sponged water on cuts every once in a while dried then carried on cut
4. Basic shape cut - now made small cuts to get to the curve

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Used the pliers to actually snap off the small pieces of blade - shows me its pretty hard

5. more fine cuts - then rounded with grinder and finished with FINE metal file
6.Shape cut out - take off burrs and flatten bottom a little on oil stone
7.use bench grinder - put angle on - just roughly copied angle on other drawknife (looks similar to chisels 15˚ i think approx)
8.drop in water bath A lot - keep cool

i alternated between grinder and water bath for maybe 30mins to get edge - was slow going but wanted a good shape and not overheat at all .

[globalmark]

Also used Belt sander for flattening , cleaning - but this didn't take much metal off - so used the bench grinder mostly -
I did also have a 40 grit sanding disc on my 4" angle grinder and used little but prefer the bench grinder as was easier to put blade in water often ..

time for the Handle - had old table leg - think its walnut ? just made length 12cm as looked comfortable for my hand - used table saw and cut slot in centre so the Handle metal part sat central in the wood and a little short of the full length

Bit old Plumbing pipe for the ferrule - cut with angle grinder then polished on bench grinder (wire wheel)
polished ferrule and wood

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Basically held ferrule approx placement - tapped with hammer to Mark the correct size to cut the wood
pencil marked the depth also and cut a square collar on bandsaw

Put in Vice the Knocked the corners off with Rasp and file till had tight fit with ferrule

Didn't photo but 5min epoxy on the ferrule
Then I cut some strips of Purpleheart (leftover from Bows) to fit the saw blade slot ready to glue in when glued blade in -
pic shows glued in blade and purple heart strip glued in at same time clamped in Vice (pushed in purple heart tight to the metal)

glue dried - measured where want Pins

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drilled pin holes to help Hold Handle - this was Harder then thought - started with small Bit lots Oil to keep cool but blade was harder then thought
but got there in the end - took a few drill bits ..

decided to glue strips in the end also hide the table saw slot -

all glue dry (5min epoxy used) - used my Rasp rough out handle shape (have a lathe and good with it but not set up since moved, annoying have to do by hand) a 5mins on the lathe or a hour or 2 by hand .

after rasp - file smooth and sand with some course paper

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Pins - I just used Nails - round ones I had tiny bit smaller then Hole - Hammered in without glue - cut off ends 1-2mm longer then the handle and hammered while holding on the Vice (bend over the ends)

picture is of completed (but before put pins in )

- needs final sand and putting some oil finish on - but didn't bother sanding that well left some dents and scrapes and sanding marks as will quickly get damaged anyway as i use my tools a lot .

the blade is sharp already but will need final sharpen with fine oil stone then I Hone on leather with honing paste until blade is shiny and can shave with it

any questions or comments post below

[Roy from Pa]

Pretty cool.

[wood carver 2]

That’s great! I love working with tools I made myself.
Dave.

[globalmark]

Thanks Guys -
Sometimes Just have to make own tools then get exactly what you want - many of the small Drawknives you buy have silly little handles this has full size handle so plenty of control ..

[Flem]

Mark, you are one resourceful Dude! 
Nice looking tool. Sometimes that old steel is coveted for its quality. Most people would have trashed it.

[BMorv]

Very cool build Mark.  Love the way it came out.   
Question about the steel:  So it's already the right hardness? 

[George Tsoukalas]

Came out great. Very impressive. Jawge

[Wolftrail]

Improvising is what its all about,, good stuff.

[globalmark]

Thanks guys

Yes steel is already hard enough - as most saw blades made some sort hardened steel - just had to be careful not get it to hot when cutting And grinding asnthen will loose hardness - if that happens would have to Aneal it - and re-harden again which is a bit beyond me , have done before but need forge or heat all steel . So best use ready hardened steel and keep cool - hence water dunk a lot ..

[knuklhed]

That is outstanding! I wish I had the vision and patience to do such nice work by hand. A thought, you might try a lower heat (propane?) torch to carefully draw back the handle sections, to make drilling the pins easier. Maybe immerse the blade section in a cold water bath while heating the handles?

[globalmark]

Hi Knuklhed

this was far easier and faster then making a Bow -
Didn't need to soften the handles but yes that would have worked also i did think about doing that actually but :-

Ok i was silly didn't use google myself before i drilled (my Bits were supposedly Titanium Coated so should work with hardened steel) -
But - MASONRY drill bits - googled it yesterday to drill a carving knife i am making - and start small lots oil and Masonry bits drill the steel super easy slow speed - and slowly get larger that was easy ..

[knuklhed]

Titanium Nitriding is a coating for the high speed and cobalt steel drill bits that reduces wear for many applications, but the carbide tips of a masonry drill will do a lot better in hard steel. Pure carbide drills, even better, and then coated, better yet, but in a hand drill, watch for any side load, they will snap oh so easily. I've been in the machining industry for a long time, and have had first hand experience getting broken drills and taps out of hard materials. Never fun. But, again, really nice work!

[globalmark]

hi

Thanks for that little bit of insight - I have a mini Pillardrill (type sits on a bench) and used slowest speed with all bits But yes the masonry bits seems to work best - as dont have other quality bits ..
cheers mark

[globalmark]

Couple more things made from same blade - actually offcuts from making the Drawknife
yew handle on Knife from last bow offcuts and brass pins from old broken door catch .

Carving Knifes - cut slot on tablesaw glued 2 pieces handle together with epoxy capturing the Tangs - then glued in end piece (so 3 piece wood handle was quickest and easiest way)
will only add pins if feel coming loose but tangs 3/4 handle length