So a while back I replaced the table saw blade in the workshop and got the idea in my head to try and make a straight razor out of it.
I sketched out a quick design and then cut it from some scraps of redwood (the same stuff I used in the ring box project - not sure if that's the correct species, but it's wood, and it's a red-ish colour, so close enough.) on the bandsaw. Fortunately I had two scraps the same thickness, so I needn't worry about the thickness of each of the scales (sides) being identical.
The blade itself was sketched out in marker on the old table saw blade and cut out with an angle grinder. Once the rough shape was done, a mix of bench grinder and rotary grinding tools were used to refine the shape.
The gap between the 2 scales of the handle was padded out using some brass sheet, cut to match the shape of the scales, whilst including cut out space both for the blade to fold in to, and to allow the tang to rotate into when the blade is opened.
This, and the scales were both epoxied together, and then two holes were drilled and brass pins added, for additional strength and their own aesthetic quality.
The third brass pin provides the hinge that the blade will pivot from to make the opening and closing mechanism.
Before the blade and handle were put together, it was easier to finish each part separately.
In the case of the handle, this meant sanding to round off the edges and
make it more comfortable to hold, and a wipe out with danish oil.
In the case of the blade this meant a lot of grinding, sharpening and honing to get it to a sharp enough edge to cut hairs. With hindsight although it probably isn't the best steel to use for a blade, it is sharp enough to shave with - it just requires frequent honing.
But, at the end of the day it works, I'm pleased with how it's turned out, and I learnt a bit more about blade making and the dark arts of sharpening and honing along the way. I also now totally get why some people fall into this particular niche rather than just more general metalworking... I'm actually quite tempted to go find some better steel and make another already.
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