Making a Knife From a Saw Blade

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Duration: 30:03

Carbide-tipped table saw blades get to a point where they can no longer be sharpened. Then what? If you’ve got old saw blades laying around your shop, here’s a project for you. Make a table saw blade knife!

Steel quality

The durability of a carbide-tipped saw blade comes from the carbide, not the steel plate. So, the plate isn’t the BEST knife making material in the world, but it isn’t bad. A file test will tell you a lot about the quality of the metal, and heating and quenching after the knife is made will help a lot. Blades that are not carbide tipped are most likely made from a higher quality steel.

Cutting and shaping the blade

You can do all the cutting with an angle grinder and cut off wheel. Make shallow and gentle cuts so you don’t snap the cut off wheel. Finalize the shape and polish the knife using flap sander discs on your angle grinder.

Get a handle on it

Use a good hardwood for the handle. If you want to add pins like we did, brazing rod works great. Adhere the handle to the blank with two-part epoxy, let it cure, then shape and seal the handle.

More than knives

This is a fun process and can be used for more than table saw blade knives. You can make other shop-made tools, like a custom shaped scraper. It’d also be fun to get a kid involved and help them make their first knife.

More on knife making

Knife making can go in a lot of directions. My friend, Tom, has been making knives for a long time and is happy to talk about it. I’ve been buying knife blanks for years and making my own handles, including all of my kitchen knives.

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