How to Make Homemade Knife Blades From Circle Saw Blades

Knives can be made from many items that might otherwise be discarded, such as lawnmower and saw blades. Circular saw blades are particularly good for making a specialty blade called an "ulu." The ulu is a half-moon curved blade designed for one-handed use and is ideal for those with arthritis, a missing arm or hand, or with severe shoulder injuries. Ulu are used with a rocking motion. The design of the ulu is based on the hunting and skinning knives of the Inuit. Pocket-size ulu, with a diameter of 4 inches or less, can be carried discreetly in a purse or messenger bag.
Going out to eat often causes embarrassment for those with hand, arm or shoulder injuries. With an ulu, it is no longer necessary to have someone else cut one's food or to choose only food that does not require cutting. The restored dignity, no longer feeling different, is priceless.

Difficulty:

Moderate

Instructions

Things You'll Need

• Old circular saw blades
• Black marker
• Wraparound eye protection
• NIOSH-approved respirator
• Bench grinder, grinding wheel
• Wire wheel
• 80, 120, 240 and 400 grit abrasive
• Buffing wheel
• Abrasive saw
• Polishing wheel
• Two ½-by-1-by-4-inch pieces of oak or walnut
• Two pieces of 1 1/8-inch thick, 1/8-inch diameter brass rod
• Vise grips
• Instant adhesive
• 5-minute epoxy
• Propane torch
• Drill press or hand drill, 1/8-inch titanium drill bit
• Rivet gun
• Rivets
• Smooth-faced hammer
• Your choice of wood finish

1. Wear wraparound eye protection and a NIOSH-approved respirator. Grind away any coatings on the saw blade using a wire wheel. Place the saw blade in the oven and bake at 450 degrees F for 1 hour. Allow the blade to cool to room temperature. This tempers the steel to make it less brittle. Repeat the tempering process three times.

2. 

   Lay out the shape of your blade using a black marker. Most circular saw blades are large enough to make at least two ulu. Make the handle area wide enough to accommodate the average man's hand, about 4 to 5 inches by 1½ inches. For sample ulu blade profiles, see the photo that accompanies this step and the Resources at the end of this article.

3. Cut out the ulu profile using an abrasive saw. Use 80 grit abrasive to remove any burrs. Sand to a brushed finish using 80, 120, 240 and 400 grit abrasives, followed by a fine wire wheel.

4. Hold blade using vise grips or tongs. Heat blade handle area with a propane torch to bright orange and cool slowly to room temperature. Use a titanium-coated drill bit to make holes for two pins in the handle. Deburr the holes with 80 grit abrasive. Use instant adhesive to secure one block of wood on the first side of the blade. Turn the blade over and use the holes in the metal as a guide to drill the holes in the wood. Secure the second piece of wood to the bare side of the handle. Turn the blade over and use the holes in the first piece of wood as guides to drill through the second piece.

5. Take two pieces of brass rod and stick them through the holes. Sand them off so that they are just barely longer than the wood of the handle on each side. Pull the pins out and coat them with 5-minute epoxy. Shove the pins back into place and tap them into place, so that just a little of the pin is sticking out on each side. Place the pin area on an anvil, the end of a vise, the side of a sledge hammer or any other hard, metal surface where you can get impact on both sides. Use a smooth hammer face to tap the pin. The brass will spread slightly. This is called "setting the pins." Sand the pins until they are flat with the wood.

6. Sand the wood until it feels comfortable and smooth in your hand. Polish the handle and use your choice of wood finishes. Ulu knives make great gifts for people with arm or hand injuries. Donate ulu knives to local nursing homes, adult day programs and sheltered workshops. If you own or operate a restaurant or lunch counter, make ulu knives available to all customers.

Resources

• History of the Ulu
• Making an Ulu: Steven Kriterdluk and Douglas Aggark: School Project