Monday, 21 September 2015

Making a Balisong with popsicle sticks.

Balisongs are illegal in many countries, why don't make yourself one with some popsicle sticks.
This is how I make mine, please watch the making of Balisong video below.


Use this video content at your own risk.
*Please do not sharpen the blade, although its make out of wood, it might still cut your hand or somebody.
Thanks for Watching :-)

Material used:
1, normal size popsicle sticks.
2, a bigger craft stick or 2 popsicle stick glue together.
3, and paper clips.

Tools:
1, Ruler
2, pencil 
3, white glue or wood glue.
4, epoxy
5, pen knife.
6, wood file or metal file
7, small drill
8, some clamps

Compare with balisong comb trainer that I have.

Balisong part name I found from internet.

Dimension Detail below:









I am using two types of stick, their dimension as in the picture.
their thickness are different too, shorter stick is about 2mm, longer stick is about 1.5mm.

The length of the tang is about 30mm, and the knife about 110mm or shorter so it can hide in the handles.

The handle rib to make the handle stronger and also added some more weight to it.
cut it short and glue it to the handle 15mm from the bottom of handle and 20mm from top.
Chamfer the inside edge, so the knife will slot in easily.
refer photo for its locations.

So, the bottom piece is going to be 15mm.

The rib of the knife were approximate, long rib about 75mm,
short one at the tang about 9mm.

Drill hole position at the tang part.

The 6mm gap can be reduce to 5mm.
The pivot pins locations are 12mm apart. 

so that handle will open and close together without gap, because it need extra space for the sidewall when open the knife. as shown below:

Notice the side wall location when opened and when closed.
The drill hole location on individual handle when closed as above.

The side wall length is 85mm
and position it 23mm gap from the handle top. (the gap is for it to clear the tang part when knife opened)

The Tang pin is about 10mm long, can be shorter if you like. and the width is the gap between the handle.

Oh, and the drill hole size is depend on the pin (paperclip) diameter you used.
the hole just need to be a little bit bigger than the pin diameter, so it can rotate freely inside.

Thanks for watching and happy building :-)





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