How to Make Japanese Hand Saws

The Japanese hand saw has a few variants with one major difference from Western saws: They cut on the pull stroke, while Western saws cut on the push stroke. Cutting on the pull stroke allows for easier placement of the blade and a more precise cut. These saws tend to be long and robust in construction, with the blade handle being made from the same piece of metal as the blade, much like a sword. We will focus on the one-piece Dozuki blade, which can be the size of a small machete.

Machete, 9 to 14 inches long that's 1/8th of an inch thick or less
Heavy duty vise
Screwdrivers, power drill, hammer (if needed)
Blowtorch
Grinder with sharpening disc and thin metal cutting disc
Gloves and welding apron
Arc welder with rods and welding mask
Two pieces of strap steel, 12 inches long, one inch wide and ¼-inch thick
40 feet of leather cord

Instructions

- 1
  Place machete upside down in the vise and tighten. You want as much of the cutting blade exposed as possible with the handle easy to access.
- 2
  Remove machete handle. Normally, the handle is held on with rivets or screws. Some are merely held on by bonded plastic. A screwdriver, hammer or drill should remove the handle quickly.
- 3
  Use the blowtorch to superheat the machete blade. Once it is red hot, begin cutting teeth in the blade between 1/16th-inch to 1/8th-inch inch apart. Use the cutting disc on the grinder. Each tooth should angle slightly back towards the handle and be about 1/4th-inch deep.
- 4
  While the metal cools, keep concentrating the blowtorch heat on the section you are cutting until you reach the end.
- 5
  Weld on the two pieces of strap steel that are 12 inches long, one inch wide and ¼-inch thick to the old handle's connecting point. You want a few inches of strap steel to bind on the top of the blade for extra strength.
- 6
  Once the blade has cooled, wrap the leather strap onto the handle to make a grip.
- 7
  Sharpen blade at your discretion.

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