Making a Survival Knife Out of a 16'' Saw Blade

In this instructable you will see how I made a survival knife from a 16 inch saw blade, with a handle made out of walnut.

Always keep in mind that woodworking & metalworking are dangerous activities that demand various safety precautions to be taken. So, be sure that you have the right PPE equipment and that you know how to use any of your power tools or other industrial machinery before you attempt to do anything on your own.

Firstly, I designed the shape of the knife on the blade and then I started cutting it.

After that, I grinded it, to give it the desired shape.

Then, I started the sharpening of the knife. At first with an 80 grit sandpaper and then with 120.

Now, I cut this little piece of metal, to use it as a stop, so that my hand won’t be touching the blade when I will be using it and also to give it a more beautiful appearance... and I formed it into the oval shape, while sharpening it.

I screwed it on a piece of wood and I started making a slot in the middle, to put the blade in it later.

Now, I started making the handle for the knife which is made out of walnut. Firstly, I rounded all the edges of this piece and then sanded it, to give it the desired shape.

To make the handle look even better and less slippery, I raised the blade up 3mm and very carefully created these slots.

I painted these gaps with a black marker, to have better contrast and then I sanded it again.

Then I drilled the handle in the middle from both sides, using a drill bit as thick as the blade, so that it has a hole at each end, in order to put the blade in it.

Now, I took these two metal tins and stacked them together, in order to put the blade inside and placed it on the gas, resulting in the blade warming up without losing any heat.

After the blade was warm enough, I dipped it into the oil, in order to harden the blade and make it stronger.

Then I sharpened the blade again and I placed it in the oven at 205°C for one hour, in order to achieve the right hardness for it to be more durable.

And I checked that all the pieces fit together without any problem.

Now, I cut this little piece of metal that I’m going to use for the bottom of the knife. I grinded it and sanded it into the right circular shape.

Then I painted all the metal parts with a matte black paint.

I placed them again in the oven at 205°C for one hour, in order to make them bake together, so that the paint won’t come off easily.

I placed them together one more time to see if everything is fine.

I sharpened the blade for one last time with a 220 & 400 grit sandpaper and tested it to see that it cuts like a razor.

I placed all the metal parts for one last time in the oven at 205°C for one hour.

And then I started the assembling. I put a very strong construction adhesive into the handle, I placed the blade in it and the little piece of metal at the bottom.

After I screwed down this little piece of metal, in order for it to fit tight on the handle, I sanded it, so that all the parts (the blade and the screws) will get to same level. Then I installed polyester putty (two component putty), to bind all the parts together, in one solid piece.