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I didn't originate this idea, but thought I would pass it along.
A workable cutoff blade can be made from a carbide tipped circular saw blade. I've also made acme cutting toolbits the same way. Just cut out one of the teeth with a sizeable steel piece on the back as indicated in the drawing below. You may have to mill the top or bottom of the blade to get the edges parallel so they can be firmly held in a tool bit holder. Then grind the carbide tip to the profile you want.
Keep in mind, some circular saw blades are pretty thin, so you need to cut a pretty wide strip to get the rigidity you need.
Chuck
A workable cutoff blade can be made from a carbide tipped circular saw blade. I've also made acme cutting toolbits the same way. Just cut out one of the teeth with a sizeable steel piece on the back as indicated in the drawing below. You may have to mill the top or bottom of the blade to get the edges parallel so they can be firmly held in a tool bit holder. Then grind the carbide tip to the profile you want.
Keep in mind, some circular saw blades are pretty thin, so you need to cut a pretty wide strip to get the rigidity you need.
Chuck