by Atman » Sat Feb 09, 2013 2:14 pm
A decent flat blade CAN be built on a tapered shaft without much difficulty. Assuming you use the box and strip method the only extra tool you might need is calipers or dividers. When you build your box layer, use the calipers to measure the core diameter at the tip and where the bottom of your blade will be. Let's assume those numbers are 3/8" and 9/16" with 24" of blade, add these to get 15/16" and lay out a rectangle on your foam with a long ruler 15/16" by 24". At one end of the rectangle come in 3/8" and make a mark. At the opposite end come in 9/16". Connect these marks and cut out the two tapered strips. The wider portion of the box layer is measured and cut the same way after dapping on the previously cut pieces. Cap and cut two blade strips as you normally would that are as wide as the base of the blade. You can either glue the strips centered over the box leaving a slight overhang at the tip, or keep them flush to one of the flats and carefully trip the excess with a long, sharp knife.