How to Make a Carving Knife From a Sawzall Blade

It is a fantastic idea to make a carving knife from a sawzall blade. A standard carving knife can be your best friend when you are using it frequently. From home to woodworking projects, multiple carving knives are used fairly. Alternatively, sawzall blades are simple, sharpen, and more effective to cut thoroughly.

Making knives is quite challenging but not impossible although carving knives are available in the market. So, how to make it? Just collecting a few materials and cutting the edge of the blade and removing excess parts. Then, making an attractive and comfortable handle.

Understanding more? 

You could read our text. This text aims to give you proper guidance on how to make a carving knife from a sawzall blade. My seven steps are enough to solve your problem.

how to make a carving knife from a sawzall blade
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7 Awesome Steps To Make A Carving Knife From A Sawzall Blade

A few days ago, I made a carving knife by using a sawzall blade. It is an amazing experience when I have worked. Nonetheless, I faced some problems while doing this risky process. Now, I will explain here seven awesome and productive steps from my experience.

1. Materials Needed

First, it is fundamental to collect the necessary instruments to make a carving knife. You know, a sawzall blade is a must. Plus, you have to include other materials such as a hammer, a file, a saw, an ax, a big knife, or a froe. Of course, you can use a new or old sawzall blade. Old blades can save you money. But, a new blade is ideal for making any kind of carving.

2. Prepping The Sawzall Blade

Now, you cut the edge of the blade to form a knife. For cutting edge, you can use a hand file, grinder, or heat treated. At this time, your blade can be heated, and watch your fingers. 

Use water to cool the heat blade. It is an easier process of handling the blade and keeping it cool when you’re working. Also, cut the length from 5 to 6cm. 

You have to create the shape on the belt sander as well as to form the blade’s bevels. Try to make a thin edge by cutting any delicate cuts. To do this properly, you must take time.

3. Choose Wood for the Handle And Preparing 

There are many options for you to choose the wood for making a handle. The Apple, Birch, Red Alder, Linden, Pear, and Green Cherry wood are suitable for use. I love Green Cherry and Red Alder woods. If you are using green wood, it allows you to hammer the blade instantly into your handle. That is why you can avoid glue and drilling. Also, you can use the Red Alder when it dries. 

Now, cut the wood or log a 15cm thick slice. Then, you get a fine shape of the end for setting the hammer the blade into. 

4. Set the Blade Into the Handle

In this step, you have to be patient because this step is quite difficult. Squeeze the blade tightly into the selected log to make a handle. Want to protect your blade from damage? Use soft metal jaws. So, try to place your handle straight. Drive the tang continuously until all is gone into the handle. Presently, your sawzall blade sits in the handle. It is nearly impossible to remove this tight handle without breaking.

5. Shape the Handle

Before creating the shape of the handle, draw the shape into some paper. Draw it from the top of the handle. Then glue your drawing onto the handle carefully. And, cover the blade by using masking tape because it is very straightforward to get off after finishing the work. On the other hand, it helps to save your fingers. 

Starting to cut the wood from outside. First, you get a rough shape rather than a finishing shape. Use an ax and a knife to do it. After completing the cut straight line, begin to round off the edges. When you win the smooth finish handle, this step is over.

6. Oiling the Handle

After designing the handle, it is also important to apply oil. But, if the handle is rough, sand the handle to smooth quickly. Leave the wood to dry enough before sanding it. Or, you can put the handle outside for one or two weeks for drying. 

Then, apply oil. Danish oil and linseed oil both are good to use. The main difference is that the danish oil takes a shorter time to dry than the linseed oil. Though linseed oil takes two to three weeks to dry, it is natural and safe for the environment.

Anyway, oil supports protecting your knife handle from dirty & stains. This process is extremely easy. Just drop the handle into oil drums.

7. Finishing Touch

Finally, the knife and handle are ready for use. So, why are you late to start using it for upcoming projects? Wait. Take a few times to dry the oil and remove the greasy feeling of the knife. After two or three days, you might use the carving knife and enjoy your cutting activities. It is a simple but useful tool. 


Can You Cut Thick Metal With a Sawzall Blade?

It depends on the sawzall blade’s types. For example, from 20 to 24 teeth per inch, sawzall is ideal for cutting thin metals. Those have between 10 to 18 teeth suitable for any medium thickness of metal. Which sawzall blades have around 8 teeth per inch used in very thick metal. 

Do You Make a Diamond Blade from a Sawzall?

Yes, it is possible to make a diamond blade from a sawzall. And, these can cut hard tile, cast iron, masonry, and other hard materials. Even provide the more accurate cuts. Remember, the best way is to successfully cut using the right type of blade.

Final Verdict

So, it is a really good feeling of using the knife that I made. Anyone who wants to make a carving knife should follow the basic principles. I have already provided some awesome and effective steps to ensure the making process. Be sure you understood the overall direction of how to make a carving knife from a sawzall blade. Now, enjoy your actions and make a knife without any hassle!

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Hi, I am Gavin Ford. I am a full-time power tools salesperson and a part-time mechanic. I help my friends and neighbors with their tools. Which one to buy, how to buy it, how to use it, methods to fix broken tools, and so on. In I will do the same for the rest of the world. You will get everything you need to know about tools for regular and professional use.

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