The LeatherSAK: Building the Perfect Swiss Army Knife

Do it yourself gear. Homemade and improved upon gear.
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The Woodsrunner
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The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Fri Jan 05, 2018 9:28 am

Good mornin!

So over the last few years, I have settled on the Swiss Army Knife platform for my everyday carry knife. 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.

What I use now: Victorinox Explorer
26695445_1650472271701377_2080043029_o.jpg
What I use most:
Large knife blade (wish it was locking)
Scissors
Flat head screwdriver
Phillips head screwdriver
Bottle opener

The rest is either very rarely needed or completely useless to me (package carrier, magnifying lens, toothpick, etc)


The victim: A Leatherman Wave
(All parts came from this one tool with the exception of the upgraded Phillips head, that I bought on Etsy, from a Leatherman Rebar)
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Carried this some, until I streamlined my EDC. I love the stright edge blade and saw. As far as inside handle tools, the little flat bit holder Phillips head is horrible, the eyeglasses screwdriver is meh, but the rest rocks.

Stay tuned as I add more pics and finish this tool off over the next week or so.

Thanks for watching,
Jayberry
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The Woodsrunner
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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Fri Jan 05, 2018 9:37 am

Disassembly time:
26654493_1650472605034677_1921055438_o.jpg
Close up of the new upgraded Phillips head from the Rebar. Perfect drop in replacement.
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End view:
26655627_1650472618368009_1504449883_o.jpg
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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Fri Jan 05, 2018 9:42 am

More Disassembly:
26613697_1650472748367996_2139327803_o.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.
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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Fri Jan 05, 2018 9:55 am

In the Leatherman Wave the straight edge and file are in one handle and the serrated edge and saw are in the other. But I put the straight edge blade and saw together on my correct handle for the build.

Got those installed as well as the new Rebar phillips head and bottle/can-opener at the bottle end.
26613804_1650472911701313_859035738_o.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!
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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by BigJesse » Fri Jan 05, 2018 11:46 am

Jayberry, I can see your attention to detail in this post. And that is exactly what makes a quality craftsman. Well done sir, I don't think I have the patience for such small tedious work. Impressed. Can't wait to see the finished product.

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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Thu Jan 11, 2018 11:47 am

Update. Tried reaming those out at my machinist friends shop. Destroyed the scissors. There is a small slot in the hole, which makes for an interrupted cut on the reamer. Not gonna try that again.

I also over thought it and attempted to anneal the flat head screwdriver befor reaming. Air cooled too fast and became brittle. Shattered that trying to pinch it in the vice. Successfully teamed the little eyeglasses screwdriver holder, but realized that I really can only fit one tool in there, without grinding out out a spring in the handle, that I am loath to attempt, especially as it is connected to the spring for the locking tools at the opposite end.

So I am sourcing a replacement flat head screwdriver, which we shall ream with attempted “annealing”. And my machinist friend is going to machine me a replacement spacer to take up the extra room.

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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Thu Jan 11, 2018 11:59 am

The shattered flat head that I am sourcing a replacement for.
E2F56648-DF39-4C32-8435-1A558C3E3BBF.jpeg



Arrow showing the useless spring I don’t want to remove. As you can see, there is enough gap to the left for the flat head screwdriver. Hence the custom spacer my buddy is making me, which will fill in the extra room on the pivot.
33994758-A499-4736-AB70-A282B171CFBC.jpeg
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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by BigJesse » Thu Jan 11, 2018 10:05 pm

One step back, two steps forward.

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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Thu Jan 11, 2018 10:49 pm

BigJesse wrote:One step back, two steps forward.

Yessir! You got it!

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Re: The LeatherSAK: Building the Perfect Swiss Army Knife

Post by The Woodsrunner » Mon Jan 22, 2018 9:30 am

Wooohooo! Friend of mine from Canada, had an extra flat head screwdriver with the very tip chipped off. A quick dressing up with a belt sander and it is good to go! He also threw in some other miscellaneous parts that need a bit of cleanup, for other mods.
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