So I finally got off my butt and got out in the workshop. This little project took about 30 minutes total, including design, layout and grinding.
First, I took a hacksaw blade and drew it’s outline on graph paper. Then, using a pencil, I drew in the lines I wanted in a small neck knife. I added a bottle opener, since most of the beer I prefer doesn’t come with a twist off cap, a small flat-head screwdriver which doubles as a ferro rod striker, a small choil more to catch the kydex sheath I plan to make than to protect my finger, enough room to wrap some 1” gorilla tape and utilizing the existing saw hole.
Then, I drew those lines onto the hacksaw blade
I placed the sawblade into my bench vise, the part I wanted to use below the grip. Then, I hit it with a 2lb hammer and it snapped right off at the vise.
I used a grinder to slowly grind away the edge profile, dunking the blade into a cut off Mountain Dew bottle of water every 2-3 seconds to keep it cool. All the grinding and the rough edge grind were done this way. I was able to eat away most of the metal for the bottle opener but not the detail work, which I did by clamping it in the vise again and using a chainsaw file.
Add gorilla tape, some 550 cord to lengthen the handle and it needs some more edge work on a stone, but not bad for a 10 cent, 30 minute project! Thanks to M4040 for the idea!