Going to make my first two knives out of my broken beloved machete

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Jan 29, 2015
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First post here, so "hello" first, and thank you for all the amazing knowledge on these forums.

Today I broke my 20+ year old Ontario Knife machete in 1095 carbon steel (I think, that's what they are made of now at least). I have carried this tool all over the US and Central America and generally abused the hell out of it. It is a beloved tool with a lot of personal history for me.

I broke it while trying to split a 14" diameter round of wet Black Locust I will make tool and knife handles out of. I was beating it into the round lengthwise with a 3 lb single jack and splitting the round into 2" sheets to dry. I honestly was surprised that it lasted as long as it did, I had no idea what I was getting into trying to split this wood by hand. I immediately ordered another Ontario Knife machete, I love this tool.

Anyway, I don't want to throw out this old warrior, so I thought I would turn it into a couple of knives. I have put handles of all sorts on many prefabbed blades, but I have never shaped a blade before. I am looking for advice on how to grind/cut this steel into full tang blade shapes. I have 4" and 9" right angle grinders with cutoff wheels, a plasma cutter, and a portaband available to cut the metal with, but I have no experience with cutting blade steel. I am looking for advice on shaping this metal without messing up the temper from people with experience, please help! What is the best tool/technique to make this happen?

http://1drv.ms/1ySEmA6
 
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Cold metal-moving techniques. Band saw for shaping the silhouette, slow wet grinding/hand filing for the edge. That's what I say!
 
Thanks! Do you have any blade recommendations for the bandsaw? I usually only cut mild tube steel, angle iron/flat bar and pipe with it and use 14/18 tpi blades because they are cheap, but I guess I would want a 24+ tpi for this?
 
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