T-Shank Blade Holder for Leatherman FREE P4

New metal pricing information

This modification adds an T-Shank Jig-Saw Blade Holder to your Leatherman FREE P4.

This mod involves extra steps by the user, please read the information tabs below.

You can also install this on the Leatherman FREE P2, if your willing to replace the main blade, or the scissors, and some of the thin implements.

Not compatible with the FREE K or T series.

#ScissorsOrSerratedBlade

If installing the T-Shank on the same side as the two thick implements: Then you need to trade one of the thick implements with a thin one from the other side.

Features:

This is a user-installed modification. It is a more involved than my bit-holders, so please read the various tabs below.

• Holds T-Shank Jig-Saw blades
• Holds blades ranging from 1 to 2 mm thick
• 1 mm blades may require use of a shim (See video)
• I recommend using it with the Leatherman Surge Diamond File or Saw
• The blade can be stored in the tool after being trimmed to fit
• The blade is held in place using two M2 screws
  • Sorry the screws cannot be included
  • Shapeways only makes and ships the 3D printed parts.
• Available in three finishes:
• Select "Silvered Bronze" for the closest fit to the tool
  
• Select "Bronze" for a fully bronze color
  
• Select "Blackened Bronze" for a contrasting dark bronze look
  
• See this page for an image of all three side by side

About the two variants:

The default "Saw or Main Blade" variant can replace the Saw or Main Blade on the FREE P4. This is the version seen in the video. It can also be installed in place of the Main Blade on a FREE P2.

The alternate "Serrated or Scissors" variant is a mirrored design. It can replace the Serrated Blade or Scissors on a FREE P4, or the Scissors on a FREE P2.

The T-Shank holder is designed to replace the saw and one thin implement.  You cannot install it on the same side as my Bit Driver mods due to the total thickness.

Taking the tool apart is a non-destructive process, however any warranty concerns are entirely up to the user. 

Alternate configurations are up to the end user. Other adjustments to the tool order/washers may be needed to keep the correct stack-up height. The T-Shank holder takes up 0.18" of the tool stack height.

Refer to the images below to reference the stack-up of the FREE P4 or P2.

FREE P4 Stack-up

FREE P2 Stack-up

T-Shank Blades:

This has been designed and tested to fit Bosch brand blades as well as the Leatherman T-shank blades. 

If you want to store a blade in the tool, it needs to be cut to a total length of 78 mm +/- 1 mm. Note: If the blade is cut too short it can pop-out when the pliers are deployed.

Screws and tap tool:

The parts requires some light metal work including tapping threads into the holes.

Shapeways only produces and ships the 3D printed parts, so the screws and tools cannot be included with your order. Please keep this in mind before ordering.

The cost of these parts from McMaster is ~$30+shipping, or about half that price from eBay

The mod requires two small screws with the following specs:

• M2 x 0.4 mm Thread
• 5 mm long
• Socket head with a diameter of <= 3.8mm
• Alloy Steel. This is stronger than stainless steel
• I recommend McMaster-Carr P/N: 91290A012 or these screws from Amazon.

You also will need a M2 x 0.4 mm tap to finish the two holes. The tap must be able to handle stainless steel. I recommend using this tap from Amazon, or McMaster P/N: 8305A77  I also recommend using cutting fluid or oil to prevent the tap from binding.

If the tap doesn't bite, you can ream out the hole using a 1/16" (1.6mm) drill bit.

To drive the set screws you need a 1.5mm hex bit, or Allen key. I recommend getting a few of McMaster P/N: 7289A11, and then cutting one down to fit in the tool, and leaving a second with your spare T-Shank blades.

Also, the Leatherman Flat Bit Kit does include a 1.5mm Hex bit. This can be stored in the tool in my Flat bit holder, or on one of my holsters.

Post Processing:

The parts are made by a bonding  stainless steel powder. The resulting part is sintered and impregnated with bronze to fully meld the two metals together. Because a powder is used: Some internal areas of the part may end up with stuck powder that needs to be cleared away using drill bits or files. If your part has an excessive amount of stuck powder, or filled holes, contact Shapeways customer service with a photo of your part for a replacement, along with your order number.

The part is similar to a casting, and shrinks a small amount during processing. The CAD model has been designed to compensate for this, but some manual filing may be needed on some parts if the parts fit too tight or bind. Use a needle file to clean up any burrs or places that are sticking. The material is stainless steel, so diamond needle files may be required.

The mounting hole may require reaming using a drill bit capable of handling stainless steel.  A 1/8" or 3.2mm drill bit may be used for this task.

Installation:

The tool must be taken apart to install this modification.  See the video above.

1. You will need two Torx T9 bits to remove the screws holding the tool together.
2. The screws need to be loosened by holding one side with a bit, and turning the other side.
3. The screws are secured using thread-locking compound, and heat may be required to loosen the compound.
4. Care should be taken to open the tool on a clean surface.
5. To install you need to remove the following items from the Leatherman FREE P4
   • Saw blade
   • Can opener (Or any of the other four small implements)
   • The Thin spacer washers. Keep one washer in the stack if your removed the File or Ruler.
   • One Thick  spacer washer (Near scale on saw side)
6. After removing those components, stack the three remaining small implements up against the serrated blade.
7. Place the spring arm next to the implements.
8. Install the two halves into the remaining space.
9. Silicone based lubricant may be added during assembly.
10. Re-install the post and screws. The tightness of the tool will depend on the amount of torque you apply during reassembly.

Design:

The result of six physical prototypes, combined with input from the folks at Multitool.org. Click the link to see how these was designed and the early prototypes.