The LeatherSAK....an all steel, all locking Swiss Army Knife from Leatherman parts.

Discussion in 'DIY (Do It Yourself)' started by TuffPossumGear, Aug 30, 2018.

  1. TuffPossumGear

    TuffPossumGear Member

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    So I am a fan of the Swiss Army Knife style knives. But there were some things missing. mainly a locking blade (yes, I know there are locking blade SAKs, but not too keen on the whole push button locking style and all), but also just too many unused tools. So I set out to build the perfect one based on my needs.

    BEHOLD, The Victim: A Leatherman Wave:

    wave 1.jpg

    Disassembly time:

    wave 2.jpg

    Close up of the new upgraded Phillips head from the Rebar. Perfect drop in replacement.

    wave 3.jpg

    End view:

    wave 4.jpg

    More Disassembly:

    wave 5.jpg


    If you open up a leatherman wave and lay it flat on the handles in an upside down T shape, there is an 8" ruler scribed on the inside. So I was careful to make sure I used the handle with the beginning (1"-4") of the ruler, for my build.

    But the bolster on the other handle had a hidden lanyard ring, so I made sure to steal it and install it on the handle side I am using.

    wave 6.jpg



    The eyeglasses screwdriver, flat head screwdriver, and scissors will all be friction lock only. No locking for them. One problem though. The holes on them are 3/16" (6/32") diameter. But the outside diameter of the Chicago bolts up at the top axis is 7/32". So I arranged with a machinist friend of mine to ream those holes out to the correct diameter for me later this next week.

    One problem. there is super thin washer between all of the inside handle tools. 0.006" thick. I can't ream out those to fit in that top axis OK with those tools that will be reamed out.... luckily the outside accessible blade also have a washer each of the correct 7/32" inside diameter. And I just happen to have two left over from the serrated edge and file tools.

    But they are 0.010" thick. No problem, my machinist friend can very easily use a air powered little sanding tool with a scotchbrite sanding pad to knock off the extra 0.008" on the flat head screwdriver. Bingo!

    OR not

    wave 7.jpeg

    That happened to all the tools I tried to ream to go in that end where the pliers head was. Oh, well. I will get a spacer machined to fit that so I can really tighten the head bolt with loctite one of these days. But it works tolerably till then.

    The LeatherSAK (swiss army knife)
    wave 8.PNG
     
    Hoover77, mmbackpacker, jdh and 10 others like this.
  2. BlueDogScout

    BlueDogScout Member

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    Great job! I like it
     
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  3. The Warrior

    The Warrior Member

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    Nice work man.
     
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  4. TuffPossumGear

    TuffPossumGear Member

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    Thanks, guys!
     
  5. Bushman5

    Bushman5 Member

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    very different! cool!
     
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  6. TuffPossumGear

    TuffPossumGear Member

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    Thanks. bushy!’

    Even better is I saw another guy who made one based off of mine, but with a Black Oxide finish Leatherman parts! :eek: It took it from cool to bad@$$!!
     
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