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Draw Knife Build along - from Old saw blade and basic tools

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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.

globalmark:
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

globalmark:
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

globalmark:
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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