who would have guessed a rusty old table sawblade could make such a nice batarang? in this project we're turning some old shop accessories,into high-speed, superhero throwing stars. after changing out this 10" saw blade, i wonderedwhat could be done with the old one. then the answer became obvious. make a custom shuriken.to get started on this project, we're gonna need a paper template, and a stick of glue.let's go ahead and glue the picture directly to the saw blade, smoothing out any creases,and let it dry for about 10 minutes. now we'll need to fasten the blade securely to a table,making sure there's something to protect the tabletop from the saw blade, because we'llbe cutting this pattern with a jig-saw. you can see these jig-saw blades have 30 teethper inch and are made for cutting metal. let's
start the blade in a groove between the teeth,and begin cutting the straight lines first. now i’m cutting very slowly, because i don'thave any oil to dissipate the heat, and going too fast could ruin the blade within minutes.you can see i continued a straight line all the way across the top, giving easy accessto the more intricate cuts inside. the tight curves are gonna take a lot of time and patience,but with some persistence, you should end up with something like this, although it doeslook a little rough around the edges. to fix that, let's gather up a couple of half-roundmetal files. i'm gonna use my bench vise to hold the batarang for better leverage, andhere you can see it definitely looks terrible. but let's go ahead anyway, and use the flatside of the small file to begin grinding down
the sharp points. the contours can be workedwith the rounded edge, and after a few minutes you can already start to see a noticeableimprovement. the larger file helps smooth and shape the bottom curves, and the goalhere is to make everything symmetrical. now, if we carefully file the edges at an angle,you can see it adds a bit of a bevel to the top of the wing. i angled both sides of thewing tips to make them look sharper, and seem a bit more authentic. this actually lookspretty awesome in silver, but let's go one step further and paint it black. now if wepush the wingtip into a piece of cardboard, the batarang should stand upright, and wecan hit it with a few shots of spray paint. make sure it's the kind that can be used onmetal, and after a couple of hours, the paint
should be dry enough to handle. at this point,it's nearly finished, and you might be thinking i forgot to paint the tip. but watch whathappens if we use something like sandpaper or a sanding sponge on the beveled edges.it re-exposes the steel, blending the unpainted tip with the outer edges once again. our superheroshuriken is completely finished, and we don't even have to sharpen the blade. i went aheadand built a throwing post from a length of 2x8, and added a dart board, to use for atarget. now, to throw a batarang, just take 3 paces away from the target, hold it by thebottom wing, and throw it with a bit of a flick in the wrist. if you did it right, itshould make one full rotation and stick firmly into the target. now if you adjust your distancein small increments, you'll eventually find
the sweet spot where it sticks perfectly upright,just about every time. a distance of 3 steps equals 1 full rotation, so from 6 paces itshould spin twice. now it's important to be safe when handling these things, and theyshould be treated with the same respect as a throwing knife or a throwing star. you cansee that after two hours of practicing, my target took an incredible beating, becausethese are the real deal. using this method, i was able to make 5 batarangs from the onesaw blade, and you can see i made each one a little bit different. well now you knowhow to turn rusty old saw blades, into a collection
3d printed gun blueprints pdf,of custom superhero throwing stars. just rememberto be safe, and never to throw them at people, or property. that's it for now. if you likedthis project, perhaps you'll like some
of my others. check them out at www.thekingofrandom.com
