In this part of the tutorial we assemble together the parts of the saw cleaver.

Part 1 of this tutorial is here

Now paint it. Give all the parts a nice thin coat of black paint.

Ok, let's put the pieces together by attaching the handle to the saw blade. Reference this picture to start.

Ok, slide the handle piece onto the blade piece in the approximate right position (as if the unit is closed like the picture above). We are going to mark it and test it before putting the holes in it.

Mark the curve with a pencil writing directly onto the blade piece.

Now rotate it to the open position. Keeping it on that curved line you drew. Does it rotate smoothly? Does anything get in the way and stop it? If it rotates smoothly from open to closed then you can move on to the next step. If it doesn't rotate smoothly you should reposition the handle on the blade and draw a new line.

This picture shows you the open position.

We are going to put three holes in this assembly. One hole is the pivot and the other two holes are for the locking pins. We use a 1/4 inch dowel for this. So if you have that then great! If you don't have 1/4 inch dowel you can use something similar like a thin pencil or the wooden part of a paint brush.

We want to make clean holes in the assembly and it can be a little bit tricky so to make it easier we are taking a 1/4 inch dowel and sharpening one end to a point. This is our piercing tool.

With your handle and saw blade all lined up nice pierce a hole right in the center all the way through all the pieces. Start with some kind of sharp tool if possible. I am using an awl.

And finish the holes with the sharpened dowel. Once the holes have all been started with a tool you can separate the hole and handle to make finishing the holes easier. That's what this picture shows.

Once the holes are pierced nicely you should clean them up with a sharp knife. You don't want burrs or excess paper or foam sticking out. This could jam the mechanism from working smoothly.

Once you have all the holes cleaned up you should coat them all with something. This will give them strength and make it more durable for the hinging and motion of it. We used mod podge. You can also use white glue. Just put an even and thin coat and twist it right into the holes to coat the foam.

Now let's cut our pins. We are using our 1/4 inch dowel. Cut three pins. One pin (for the center hinge) is 3/4 inches long. And the other two pins are one inch long.

Let's continue with the tutorial

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