The design of this ax consists of three parts.
The shape of the blade was borrowed from the tomahawk - ax, which was used by Native Americans and European colonists. But you can change its shape by adding a few spikes or a hammer on the butt. The ax blade will be glued to the handle and sealed with rivets.
First, I wanted to make a suitable hole in the blade as a bottle opener. As a result of test drilling, it was found that it was impossible to make a hole with a conventional drill, so I changed the look of the bottle opener.On the image you can see both options. The new type will be made in the form of a hook of a special shape.
I wanted the ax to be with a saw, and thought that it would be nice if it hides like in a folding knife. From the handle and it can be expanded using the notch for the fingers. The saw will hide between two pads. The shape of the metal part of the handle will allow the saw to be fixed in both the open and folded positions. After the design was selected, I tried it on the blade of the circular saw so that the dimensions fit. Materials and tools
This ax is made from a used circular saw and hard wood that I had. I had to purchase only a folding saw blade. It has already been hardened, so it did not need heat treatment. Materials:
- Old saw blade.
- Solid wood beams (approximately 50 x 40 x 300 mm).
- Epoxy resin.
- Large nails for use as rivets.
- Folding saw blade (I used 200 mm).
- Bolt, nut and washer.
- Angle grinder (don't forget about the toolsprotection!).
I transferred the outlines of the ax and the metal part of the handle to a circular saw and cut them with an angle grinder with a thin cutting wheel. Then with the help of a grinding wheel, an angle grinder and files, I completed the formation of the elements. The final shape of the metal part of the handle can be given later.
Manufacturing of the handle
You can glue the template to a wooden workpiece and cut two overlays. I used my CNC milling machine.
Hardened steel drilling
I did not have a drill for metal from carbide materials, so I was not sure how the process of working with a hardened ax would proceed. I came across a video where it was told that you can use a sharpened drill bit for concrete to drill hardened metal. So I did, and everything worked out pretty well.
Adding a bottle opener
Probably, this is the most irreplaceable detail of an ax! Whenever I go hiking, usually in the evening around the fire, my friends and I miss a couple of bottles of beer. To open them with stones and tree branches is very inconvenient. Therefore, I thought that this detail would be very helpful. I transferred the outline of a regular opener to the ax blade and punched a recess over it. It works beautifully :)
Drilling a handle
Next, I drilled holes in the handle and checked to see if everything is right. The metal part of the handle should perform the function of a spring that will fix the saw blade. If it is too elastic, it can be made thinner. At first I used the metal part of the handle as a template for making holes. Then he fastened the two pads with the help of clamps and then drilled a through hole. Thus, all the corresponding holes were in one line. In order to connect the parts of the ax without gluing, I used bolts. So you can check whether all the details of the ax are suitable and whether the saw is correctly folded.
Sharpening the blade
After the blade was outlined, I used an angle grinder with a grinding wheel for rough handling. Then, for finer work, a file and a grinding machine went into motion (use water to cool the blade). The final sharpening was done with a grinding wheel of a sharpening machine. I am not an expert in sharpening an ax blade, so you can do it in another way. An ax will mainly be used to divide a tree into smaller parts, so I did a little test of its functionality.
Bonding and riveting
Covers are fixed with two-component epoxy resin and 5 mm steel rivets (I used large nails).Before all the glue, do not forget to make notches for the fingers for easy folding of the saw. For better adhesion of glue and metal surface, it can be made more rough using a file. Apply the glue only to the ax and the upper part of the metal part of the handle. In the handle, the plate should function as a spring.
Shaping the handle
Now, when the overlays are glued, it's time to give the handle a convenient shape. I used a rasp, files and sandpaper. Using an emery paper tape, it is convenient to work the edges.
Polishing and debriefing
I finished making polishing oil and installing saw blade. The ax weighs about 300 grams in total, so it’s comfortable to carry around.In the future, I would like to make a leather case for him. I have never had a chance to take it on a hike, but I tried it in the nearest landing. Saw can be cut branches, and an ax to prepare them for a campfire. The opener works, so the project can be considered successful :). I hope you enjoyed reading this master class.
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