Challenge: Make a handsaw given only a blade

Challenge: Make a handsaw given only a blade [∞]

Objective

Students will use a provided saw blade and natural or salvaged materials to craft a functional handsaw. This challenge develops problem-solving, creativity, and practical craftsmanship skills essential for survival scenarios. Materials Needed Provided:

   Saw blade (toothless strip or salvaged blade with teeth intact).
   Metal wire or strong cordage (optional, for securing blade).

Natural or Salvaged Materials:

   Handle Material: Sturdy branches or wood pieces (hardwoods like oak, ash, or maple work well).
   Fasteners: Natural cordage, vines, or salvage items like nails or screws (if allowed).
   Tools:
       Hatchet or handsaw (for shaping wood).
       Whittling knife.
       Drill (manual or improvised awl).

Safety Gear:

Gloves, goggles, and a first aid kit. Preparation

   Set Up Workspace:
       Prepare a safe crafting zone with cutting and assembly stations.
       Provide demonstrations of tool use and safe handling of sharp objects.

   Teach Basic Principles:
       Explain how saws function and the importance of stability and ergonomics in handle design.
       Show examples of basic saw designs (e.g., bow saw, straight-handled saw).

Challenge Instructions Step 1: Design the Handsaw

   Decide on a saw type (e.g., straight handle or bow saw).
   Sketch or plan the design before starting.

Step 2: Craft the Handle

   Straight Handle (Simple):
       Select a straight, thick branch (about 1.5–2 inches in diameter).
       Carve a groove to seat the saw blade securely.

   Bow Saw Handle (Advanced):
       Find a branch with a natural curve or assemble a bow shape from multiple pieces.
       Use cordage to create tension across the bow to hold the blade.

Step 3: Attach the Saw Blade

   Drill or carve holes in the handle to align with holes in the blade (if present).
   Secure the blade using cordage, natural fiber, or metal wire.
   If no pre-drilled holes exist, carve notches to seat the blade tightly and lash it in place.

Step 4: Test and Refine

   Use the saw to cut small branches or wood.
   Adjust the handle or blade attachment for stability and comfort.

Challenge Variations

   Timed Build: See who can create a functional saw the fastest.
   Material Scavenger Hunt: Incorporate a scavenger hunt to find natural materials for the handle.
   Durability Test: Test saws on progressively thicker wood to assess strength and effectiveness.
   Design Creativity: Award points for ergonomic design or innovative attachment methods.

Debrief and Reflection

   Discuss what worked well and what could be improved.
   Reflect on how designing and building a tool enhances problem-solving and adaptability.
   Share insights into teamwork and resourcefulness during the challenge.

This challenge is ideal for fostering ingenuity and engineering skills while emphasizing the importance of functional tools in survival situations. It aligns with Acton Academy's learner-driven approach and encourages practical application of knowledge.