Thread: Making wood scale question

To make the rasp you need from 1/2" to 1" bandsaw blade. Cut at about 4-6" intervals. Stack pieces of blade together. If the tpi is low you can stagger the teeth. With thinner blades they need to be shorter length too. Stack until you make the width you want. Use a little CA glue along the backs of the blades. If using a thicker blade you can drill through the blades and add a support bolt or rivet. Wrap one side with tape. This depends on whether you want a push or pull cut on the rasp.
I do have longer ones, but they require more support rivets (brass rod).
Tpi regulates how heavy it cuts.
Remember to sharpen before assembling and don't get CA on the teeth.
Almost all of my carving rasps are made by this method. I even have a couple with hack saw blades.
If you want to get creative use very thin blades on a curved piece of wood add epoxy and see where it goes.
Also if you can't find blades that thick for free in the tpi you want just epoxy to a flat wood backer for support.