Rough Blade Shape without a bandsaw...

K

killteamTRS

Joined
Nov 30, 2007
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I've seen some interesting ways of getting the rough general blade shape through drilling and such without a band saw and was hoping for some helpful hints/tutorials on how to do it. I don't have a band saw and want to see what I can do without one!

Thanks
 
4" angle grinder with cut-off and grinding wheels and lots of safety gear. I have a metal cutting bandsaw and actually prefer the angle grinder. As long as you follow the safety rules, there isnt much you can't cut. Plus cut-off wheels and grinding wheels are a buck or so a pop. Much less than bandsaw blades...

This is post angle grinder cutout. Took about 10 minutes.

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yep angle grinder for me as well
wear your safety goggles, mask and ear protection
 
My first few dozen knives were all cut by hand with a hacksaw then profiled on a grinder. A bit of elbow grease, but not all that bad
 
I too use an angle grinder. I cut straight lines with a cut off wheel just outside my layout. Then I switch to a flap disc wheel on my angle grinder and finish it to the layout. I find the flap disc wheel to work better than a grinding wheel as it removes material quickly yet doesn't try to dig in at any certain spot.

Chris
 
I've tried a hacksaw a few times and to say the least it's tiresome and very very time consuming so I was hoping for an easier option! The angle grinder sounds like an excellent idea though and considering they're less than 50 bucks, I think I'll have to pick one up!
 
High tension hacksaw for me as well, a good blade and lube to keep I cool, it goes quite quick. Regular hacksaws suck. Must be a high tension hacksaw.


-Xander
 
Be careful with thin cutoff disc. If they bind in a cut because you are no longer vertical, the result can be disastrous. There was such a disaster posted on weldingweb.com that showed a portion of a 9" disc imbedded in a guys face. While angle GRINDERS can cut with a cutoff disc, you realize that this is not the intended purpose when you see these fascial disasters.
 
I have used a hobby hack saw and bench grinder. It's not very efficient or precise.
 
fast14riot said:
High tension hacksaw for me as well, a good blade and lube to keep I cool, it goes quite quick. Regular hacksaws suck. Must be a high tension hacksaw.


-Xander
Click to expand...

I also use a high tension hacksaw. Biggest problem is blades. What do you use (TPI, brand, composition) and where do you get them. Next set will be from Aldo's 52100.

OT
 
I picked up the harbor freight portoband for $60 with a coupon, best purchase I'd say I've made. Got a 3 pack of blades at menards for $15 and it was all downhill from there. The blades last me about 2-3 months before I have to get more.
 
Old Traf said:
I also use a high tension hacksaw. Biggest problem is blades. What do you use (TPI, brand, composition) and where do you get them. Next set will be from Aldo's 52100.

OT
Click to expand...

Lenox Bi-Metal blades, 24tpi from Home Depot or other friendly hardware store.


-Xander
 
High tension here too, but I've been using Nicholson 18t high carbon blades (per the recommendation on the package).

It's takes a bit of effort. Maybe I'll try a different tpi count.
 
i like that klein high tension hacksaw and lenox blades. the buck bros ones wont cut it. standard tips for this is: Try to be cutting no more than an inch away from where the steel is clamped in the vise. You can cut fast but beware the more heat the less life of the blade. The blades are designed to cut one way only. Let the saw do the cutting!
 
Hacksaw worked just fine for me. Then I switched to 4.5" angle grinder cut-off wheel. I've made about 50 knives with a 1/16" cutoff wheel from Home Depot for profiling and I've never had a wheel come apart. They are quite strong. I also cut in straight lines, of course. And I wear safety gear.
 
I decided to go check out the sales over at home depot and picked up a 4.5" angle grinder for 30 bucks plus a few cutoff wheels. Thanks guys!
 
Started out with a hacksaw and bench grinder. Then switched to a band saw. I tried a 4.5 cutoff disc on an angle grinder and have stayed with it. The cut off is much faster then the band saw. Remember to wear all the safety gear.

Make sure to use discs that are rpm rated for your grinder. I know a guy who used a low rpm disc on his high RPN grinder and it blew up. A year later and several operations and he can almost use his hand again.
 
PT Doc said:
Be careful with thin cutoff disc. If they bind in a cut because you are no longer vertical, the result can be disastrous. There was such a disaster posted on weldingweb.com that showed a portion of a 9" disc imbedded in a guys face. While angle GRINDERS can cut with a cutoff disc, you realize that this is not the intended purpose when you see these fascial disasters.
Click to expand...

I've seen too many broken grinding discs sticking into people, and read too many reports about bad accidents to see them as a safe tool in the hands of inexperienced users. This is exactly why I chose a jigsaw with the right blades over an angle grinder. On the other hand, the Harbor Freight portable bandsaw is something like $120, $80ish if you find it on sale (I just looked, $81.99 on sale). A stand or vise fixture can be made dirt cheap.
 
I completely agree that with so much better alternatives, an angle grinder used to cut out blades is just a risk not worth taking.
 
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