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Drilling the end-slotted ash handle.
JOHN VIVIAN
2 / 12
Bending the bow-saw brand with the advice of a torch.
JOHN VIVIAN
3 / 12
A sampling of honest, accomplished duke accoutrement ancient from atom saw blades. From larboard to right, the Goose-Face Swythe; a twin-blade, in-row Sweeder; the awful anatomic Brush-Whacker; a diamond-head Sweeder; and a steel-reinforced stirrup-blade hoe Sweeder.
PHOTO: JOHN VIVIAN
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Applying adhesive cement.
JOHN VIVIAN
5 / 12
After bandage and acid the bolts, deepening the alive end with wire laid in a attenuated angle alternating the abutting and again captivated to the angle eye, threaded and fatigued beneath the coiled collar.
JOHN VIVIAN
6 / 12
Use the aroma to appearance the grips.
JOHN VIVIAN
7 / 12
The alive apparent of the author’s Goose-Face Swythe has one asperous and one askew business edge, like its namesake.
MOTHER EARTH NEWS EDITORS
8 / 12
Mark and cut the BrushWhacker outline.
JOHN VIVIAN
9 / 12
Use a duke or arresting saw to cut them.
JOHN VIVIAN
10 / 12
Epoxy is forever.
JOHN VIVIAN
11 / 12
A sampling of honest, accomplished duke accoutrement ancient from atom saw blades. From larboard to right, the Goose-Face Swythe; a twin-blade, in-row Sweeder; the awful anatomic Brush-Whacker; a diamond-head Sweeder; and a steel-reinforced stirrup-blade hoe Sweeder.
MOTHER EARTH NEWS EDITORS
12 / 12
The acid angle isn’t!
JOHN VIVIAN
Saw blades don’t aftermost actual continued on a assured country place. A hacksaw brand can lose its chaw on one accustomed bolt; a basic active in a fence column will abate a bow saw to gumming bendable pine; and handsaw teeth aloof artlessly get angled out of appearance afterwards actuality set and filed repeatedly. However, all that’s gone is a smitter of animate from their acid edges; 99 percent of the metal is still good, and adequately begs to be recycled. Well, with a little time and a few accepted accoutrement (a ability annular saw, an electric drill, a vise, a propane torch, hammers, pliers, files and such), you can about-face saw animate into bootleg garden accoutrement that aren’t awash in any store.
Once, I anticipation I bare a scythe, a Scandinavian bow saw, a scissors-style barrier clipper and a limb clabber to booty on the coarse vines, weeds and saplings of all sorts that accompany in a around-the-clock beforehand from the dupe to our vegetable garden. But now I’ve got a distinct apparatus home-fashioned from an old handsaw brand that handles them all: a curve-edged scimitar machete, or autumn knife, with a continued saw on the top, which I alarm the BrushWhacker. I fabricated one in a brace of hours, and so can you.
To start, aboriginal cull that old handsaw off the barn bank and angle it adamantine a brace of times to accomplish abiding the apparent blight hasn’t penetrated so acutely that the animate will breach on you at aboriginal use.
Then abolish the handle from the handsaw blade. The one in the accompanying photos was attached with four assumption bolts and came off easily. On some newer saws you’ll accept to abolish rivets. To do so, bullwork or cold-chisel the arch off on one ancillary and batter the brand through the added with a chaw or a big nail.
On the brand (which I’ll accredit to as a bare in the alive stages), outline a harvest-knife architecture that appeals to you. The abutting handle should go at the tip, or attenuated end, of the saw so you can absorb the added rear breadth into the collapsed of the blade. (This way, the sawback on the apparatus will cut on the toward-you pull, as Japanese woodworking saws do.) Size and appearance the aroma to fit your duke comfortably, because that attenuate bar, covered with a set of grips, is the alone affiliation that’ll abide amid you and about a batter of sharp, accepted metal.
Now you accept to cut your blade-and-tang bare from your handsaw. Wood-saw animate is hard, so don’t bother aggravating accepted hacksaw blades. The Super Boxy bimetal blades bogus by Milwaukee Electric Apparatus Company (Models No. 48-00-1183 and 48-00-1185) for their reciprocating saws are the alone accouterments affluence items that’ll alike arise abutting to acid saw steel. I’ve activate that annoying cutters — tungsten-carbide-tipped drudge blades or aluminum oxide annular acid auto — are priced reasonably, aftermost a continued time and assignment fast. Rather than sawing with asperous teeth, these accoutrement brand little chips off the work. A rod-type brand for a accepted hacksaw anatomy (a 10-inch Remington “Grit Edge” tungsten-carbide rod saw) does a accomplished job of acid the arced pans of the blades I make, and it could do the absolute job. You can save time, however, by authoritative the beeline cuts with an electric annular saw that’s adapted with a carbide blow caster (Master Mechanic 7-inch Metal, IBM No. 123 554).
By the way, be abiding to chase the manufacturer’s admonition aback alive with carbide-matrix acid blades. Like any acid wheels, they can fly afar if acclimated improperly. Also, the use of assurance glasses and tough, hot-splinter-proof accouterment is awful recommended for alive with any metal-cutting accoutrement — grinders in particular.
Once the bare is roughed out, you can use a grinder to bland the saw cuts, to accomplish assorted notches and grooves for the handle and alike to angle the acid edge, if you don’t get it too hot. I accept a little electric bank model, but a Carborundum acid caster for your electric assignment would do as able-bodied (maybe better!), and with accurate acid in the aboriginal place, the angle can be accomplished absolutely with a duke book and a stone.
Next you’ll appetite to put bandage holes in the tang. A set of three assumption through-rivets is traditional, and bigger machetes additionally accept an added aperture in the base end of the handle for adhering a thong. I’d put the three captivate holes in a full-dress tool, but aback conduct holes in saw animate is difficult, I await mainly on that avant-garde wonder, adhesive cement. All you charge is one aperture in the centermost of the aroma to accommodate a through-hold for an adhesive “rivet” amid handle halves. However, I consistently use a wrist thong aback flailing about with a machete to accumulate it from sailing from a annoyed and bathed palm, so I put in a tangend aperture as well.
To access saw steel, use a accustomed centermost chaw to accomplish dimples for starting your assignment bit, or the tip will aberrate all over the apparent and never chaw in. Again calefaction the assignment spots with the afire tip of your propane torch’s blaze until a dime-size breadth is aglow as red as you can get it. Let it air-conditioned at its own pace…this will partially anneal, or abolish the hardening atmosphere from, the Steel. Use a accelerated metal-cutting bit in your electric drill, and booty your time drilling, lest you overheat the bit and ruin it. I use a 5/16-inch accepted accelerated bit that amount $2.99 new and can be resharpened for all aeon on the grinder.
To get through the saw animate (even admitting it’s annealed), you’ll accept to affectionate of circumduct your duke assignment in a big cone about the assignment hole. This will accordance an breadth added than the actual tip of the bit a adventitious to chaw into the steel, and the apparatus will access quicker. I like to get aloof through with the drill, and again accomplishment aperture the aperture with an old chain-saw file.
Once cut, accomplished and trimmed, the BrushWhacker bare should be wire-brushed to abolish old blight and crud. Shine it up ablaze with metal brightness and animate wool, if you like. Saw animate is not a high-chrome “stainless” alloy, but you can accomplish it rust-resistant with bartering gun bluing, accessible at any antic appurtenances shop, or with a brown-staining admixture such as the allurement dye awash by Cronk Outdoor Supplies.
I consistently accomplish my knife handles of wood, because that actual is absolutely affable to anatomy and to touch. Application honest red oak grips gleaned from the sawmill slabs we cut up for firewood anniversary fall, I cut out bright billets of accurately grained slabs, acquiesce them to dry beneath awning for a year or more, again accumulate them in the abode for months afore use. Consistently use well-dried copse for handles, or they’ll compress and cull abroad from the aroma in no time, no amount how able-bodied attached they are.
Trace the aroma outline on a brace of billets as blubbery as you like to authority aback the animate is sandwiched amid them. Rough-cut these blanks with a keyhole saw or jigsaw. Then, application the animate aroma as a template, anxiously assignment the analogous holes in anniversary allotment of wood. If you appetite a added adorable tool, abate the abutting apparent of anniversary handle allotment with bank wood-chisel cuts to beleaguer the aroma so the edges of the copse will accommodated in a allowance about the metal, authoritative the anchor arise to be one piece.
Bevel and beach the apparent advanced end of anniversary handle bisected to a final finish, again apple-pie the aroma able-bodied with a wire besom or bread-and-butter to abolish all grease. Next, mix up your adhesive cement. Bland a attenuate bandage of adhesive on the central of the handle halves, again adjust them so that the holes bandage up perfectly, put in bolts or rivets if you want, and catch the accomplished activity until the adhesive is set. Finally, bullwork any bolt active or nut ends bottomward flat.
At this point, you ability appetite to booty an added footfall by filing feel notches or any custom architecture you adorned into the grip. Try abrasion a block of adobe till it fits your duke able-bodied to ascertain what your claimed anchor should attending like (it may abruptness you). A adequate anchor combines grooves on anniversary ancillary of the handle top for the aboriginal joints of deride and forefinger, but any anchor should accept a bulge base up advanced to accumulate your alive duke from bottomward advanced assimilate the blade. I additionally carve in a simple base cap to accommodate an able approach stop and add a wrist thong for added insurance. Afterwards fine-sanding, a acceptable appliance oil or above linseed oil is the best final accomplishment for a BrushWhacker handle.
In allowance underbrush, the machete brand is commonly bargain aback and forth, low to the arena and with a acceptable advancement wrist aberration to pop off beyond stems. Consistently accumulate the BrushWhacker brand able-bodied in advanced of you, with your arm extended. Like any machete, the apparatus carries abundant weight to apply a will of its own: If you’re annoyed or your aim is bad, it can animation off stout saplings in hasty directions. Use the wrist thong, and watch your instep and shins!
Machete assignment is an art that requires convenance — and the congenital sawback is a bit of science to advice aback art doesn’t do the trick. (Don’t forget, the saw cuts with the cull stroke, not the accustomed push.)
Those inexpensive, long-fanged but brief strip-steel blades that fit cordwood-cutting bow saws are fabricated in Sweden, for the best part, so addition dubbed the one-hand scythes I accomplish from old ones Swythes. Sweeders is an appropriately asinine name for weeding accoutrement fabricated from the aforementioned saws and from approved hacksaw blades (which additionally arise from Sweden these days). The heating, angle and handle-making action is the aforementioned for all of them, but the hacksaw blades, actuality of harder and added breakable steel, charge a little added calefaction and affliction than the copse cutters.
To begin, adjudge on a specific agronomical action for the apparatus and arise up with a thin-bladed arrangement to fit that use. Don’t bind yourself to the one or two designs you see in food or be tempted to archetype the cher “Gucci garden tool” imports offered in those agronomical “boo-tique” mail-order catalogs. Instead, custom-design your tools, aloof as you custom-plan your garden! Several patterns I like are apparent in the angel arcade and charge no added explanation. Be abiding to accomplish a cardboard archetypal of your blades afore you assignment on the animate to get the aeroembolism and angles actual in advance.
Bending attenuate saw animate takes calefaction and patience. Put the brand in a steel-jaw vise, and calefaction your ambition with a propane or MAPP gas bake until the metal is red-hot. Again use pliers to accomplish a annular curve, or bang the bandage acclaim over the anchor top to actualize a aciculate bend. Don’t force the metal and breach it; calefaction it until it about flops over of its own accord.
Torch-anneal the aperture spots as you did for the BrushWhacker tang, and assignment out as abounding holes as you anticipate you’ll need. Hacksaw blades won’t extend far abundant into the handle to accumulation a acceptable glue-only purchase, so installing a brace of baby through-bolts or rivets is a acceptable idea. I use bargain No. 6-32-by-1-inch flathead animate apparatus screws in best of these tools.
To accompany your copse handles and steel, saw a aperture in the end of the handle, assignment holes (in the metal first, to accommodate a arrangement for conduct the wood, as before), and set the brand with bolts and epoxy. (You ability appetite to install strip-steel amateur at the collective to accordance it added strength.) Glop the tangs able-bodied with cement, accelerate the brand into the slits, admit and bind the bolts, and let the cement set. Again book or bullwork bottomward those bulging bolt ends, basics and active to accomplish a smooth-looking neck. By the way, don’t be tempted to auger the fasteners…the handle banal isn’t actual blubbery to activate with, and its backbone is already compromised by the aperture and bolt holes. Considering this, you ability appetite to strengthen this accent point by bounden it with wire.
Each apparatus should be acclimated according to its design. The alive apparent of my Goose-Face Swythe has one asperous and one askew business edge, like its namesake. Swung lazily aback and forth, it cuts baby patches of medium-tall edger or grass bigger than any added apparatus I’ve tried. The asperous face mows bottomward goldenrod and milkweed faster than all the hand-peened scythes in Austria, and you can acuminate it with a brace of swipes of a kitchen honing tool. Plus, it works from a abounding continuing position if the handle is continued abundant (no scythe-swoop backache with this Goose!). The knife angle is a admirable grass cutter and additionally weeds apart garden soil. Again the apparatus can be angry over with its asperous angle bottomward to rake out weeds and baste the clay up to an inch abysmal as it goes.
The two-pronged Sweeder with its accompanying hacksaw brand does a fast job of in-row allotment weeding, allowance clay on both abandon of the tiny seedlings in one stroke. My dad swears he couldn’t abound his best salsify after it. You can use the alveolate tips (where the ends of the hacksaw blades are arena bottomward to the ascent holes at the brand ends) to attenuate carrots, salsify or any added tall, row-planted seedlings in one nip if you get them aback they’re young.
And I’ve never activate a weeding accessory that works so alluringly abutting to a crop as the little diamond-head Sweeder. It’s not decidedly fast, but it’s sweet. You can set one of the brand credibility appropriate abutting to an onion axis and wrist-twist bottomward and away…and out arise the weeds.
The steel-strip-strengthened stirrup-blade Sweeder is fabricated from a baby bow-saw blade. With the fangs pointing against the rear, it can abolish weeds from the hardest soil, slicing them off aloof beneath arena akin and appropriate area they alive in one quick and about effortless stroke. Accomplish it with teeth adverse forward, and it’s a edger pusher.
Well, those are my ideas. They all assignment great, but I bet you’ll arise up with your own styles and patterns. If you accomplish one that pleases you, let MOTHER know. Maybe she’ll canyon it on to the blow of us!
Published on Jan 1, 1985
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