In this guide, I will show you how to make a saw blade machete from a recycled 82CrV circular saw blade using basic workshop tools. This DIY tactical project covers the entire process from raw material preparation to final sharpening.
A saw blade machete can be a highly effective cutting tool for outdoor activities such as bushcraft, survival, and camping. Circular saw blades made from high carbon steel are excellent candidates for handmade blade projects due to their durability and wear resistance.
Materials Used in This Project
To build this handmade outdoor blade, I used the following materials:
- Recycled circular saw blade (82CrV steel)
- Epoxy adhesive
- Brass pins
- Sandpaper (80–400 grit)
- Ferric Chloride (FeCl₃)
- Hardwood handle scales
- Belt grinder
- Drill press
- Files and polishing tools
Advantages of Using a Saw Blade Machete
A properly crafted saw blade machete offers multiple benefits compared to factory-made cutting tools. The high carbon composition of 82CrV steel helps maintain sharpness for extended periods, making it suitable for heavy-duty outdoor tasks.
Because of its recycled origin, the saw blade machete is also a cost-effective and sustainable option for DIY makers who want to create custom survival gear using scrap materials.
Blade Design and Planning
Before starting the build process, it is essential to create a functional blade design based on intended use. This tactical-style outdoor knife was designed with a wide cutting surface for efficient chopping and slicing.
A custom-designed saw blade machete should provide a balance between strength and maneuverability. Proper planning ensures improved ergonomics and better performance during field use.
Cutting and Shaping the Blade
The initial profile of the saw blade machete was cut from the circular steel disk using an angle grinder. After rough cutting, the blade edges were refined to remove excess material and achieve the desired geometry.
This shaping stage is crucial for ensuring that the final handmade cutting tool maintains structural integrity during demanding survival tasks.
Grinding the Bevel
Using a bevel grinding jig, the primary cutting edge of the saw blade machete was formed. Controlled grinding helps prevent overheating and preserves the hardness of the recycled steel.
A well-ground bevel improves cutting efficiency and extends the functional lifespan of the blade.
Surface Finishing and Protection
After grinding, the blade surface was sanded using progressively finer grit levels to remove scratches and prepare it for chemical etching.
Ferric Chloride (FeCl₃) was applied to the saw blade machete to enhance corrosion resistance and achieve a protective finish.
Handle Installation
The handle scales were attached using epoxy and brass pins for structural strength. Proper handle construction improves grip stability and enhances control during use.
A durable handle is essential for any saw blade machete intended for outdoor survival applications.
Final Sharpening and Testing
The final step involved sharpening the cutting edge and testing the blade on various materials. The completed saw blade machete demonstrated strong performance in chopping and slicing tests.
This DIY project shows that a recycled steel blade can be transformed into a reliable handmade outdoor tool with the right techniques.
Conclusion
Building a saw blade machete from recycled steel is an excellent way to create a custom tactical tool for bushcraft and survival use. With proper design and finishing, this type of handmade blade can rival many commercially available options.
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🔧 Why Use Recycled Circular Saw Blade Steel?
Circular saw blades made from 82CrV steel offer excellent hardness and wear resistance when repurposed into cutting tools. This high carbon alloy is widely used in industrial blades due to its durability and ability to maintain a sharp cutting edge over time.
By recycling used saw blade steel into a handmade machete, DIY makers can create a highly functional survival tool suitable for bushcraft, outdoor activities, and workshop use. With proper grinding, beveling, and finishing, recycled steel can rival commercially manufactured machetes in both strength and cutting performance.
This DIY machete project demonstrates how discarded industrial materials can be transformed into practical and reliable tools for everyday use in outdoor environments.
82CrV steel is a high carbon chromium vanadium alloy widely used in industrial cutting tools.
According to tool steel classifications, chromium and vanadium improve wear resistance and edge retention.
For achieving the correct edge geometry, you can also calculate grinding angles using
Knife Angle Calculation Tool .