Make Your Own Giant Razorblade Handle With This Handy Guide
Do you happen to have a giant razor blade lying around? How about turning it into a useful tool by adding a custom-made wooden handle?
Does this sound interesting? Then follow this simple guide to build one for yourself.
Like any project of this nature, you'll first need some stuff to get you started.
Tools and equipment needed
- 1 big razor blade
- Lengths of wood (e.g. Bubinga)
- Double-edged pull saw
- Metal files
- Kydex sheet
- Nuts and bolts
Step 1: Prepare the rough handle
The first step is to source some suitable lengths of wood to make your giant razor handle from. Once you have found some, place your razor blade on one end and mark off where you want it to be attached.
A little further down the wood also mark out roughly how long you want the handle to be. In this case just over a hand's width from the rearmost edge of the blade.
With the dimensions sketched out, cut out the shape of the wood you need.
Next, grab your joiners/builder's square and mark off a line around the entire perimeter of the wood the same length as the razor blade. Then draw another line through the center of the piece of wood from the line to the edge of the wood.
Grab your saw again, and cut through this bisecting line.
Next, take the length of wood and secure it inside a vice with the cut line facing directly upwards. Grab some files and begin to widen and smooth out the cavity to the same width as the razor blade.
Use a variety of files to complete this step as needed.
Test it at regular intervals by placing the razor blade inside to ensure it fits firmly. If not, adjust as needed.
Step 2: Begin to shape the handle
With that complete, grab your pencil and begin to sketch out the rough shape of the handle that you want. Try to make it as ergonomic as possible.
Once you are happy, cut off the excess using a saw as needed.
You don't need to be too exact here as we will be refining the shape later on, but try your best to follow the lines you sketched.
With that complete, grab your files again and begin to refine and smooth the handle's shape. As before, use a variety of sizes and shapes to get the handle shape to your liking.
Once complete, grab your Kydex sheet and mark out the central holes of the razor for one-half of the razor. Next, cut out the shape using a hacksaw, as needed.
File down the cut edges using your files or a Dremel as needed. With that complete, insert the Kydex into the hole of the razor.
Step 3: Continue to refine the handle
Next, round off the ends of the razorblade end of the wood handle, and insert the razor blade (with Kydex insert) into the handle. Once complete, drill pilot holes through the handle, holes, and out the other end of the wooden handle.
With that complete, remove the razorblade and countersink the holes as needed. Once that stage is complete, bevel off the edges at roughly 45-degree angles of the handle from top to bottom using your metal files.
You can also use a Dremel to help you out here if required.
Continue until you are happy with the overall shape and form of the handle. With that complete, grab some sandpaper and begin to smooth off the surface of the handle and razorblade head.
Step 5: Varnish the handle and assemble
Next, grab your wood varnish and work it into the handle using a clean cloth. Work the varnish into all crevices and apply it using a smooth and even motion.
Keep working the varnish into the wood until all exposed surfaces of the wood have been sufficiently covered.
Wıth that stage complete, add the Kydex insert once again to the razorblade and insert the blade into the handle's slot. Secure the blade into place using suitably sized bolts as tighten as needed.
With that, your DIY wooden handle for your giant razorblade is finally complete. Now you can sit back and admire your handiwork.
If you enjoyed this project, why not up the ante and try something a little more complex. How about a fist hammer?