I've cut throught blades with a hacksaw. You will need a good blade in your saw mind, molybendium. Some of the 10 pack hacksaw blades go blunt on screws! And filing, yup
Nah, no 2x72, those short fat belts heat up too fast, need long thin belts so that they stay as cool as possible.
So probably easier for him to use the belt sander he has access to already - not that terrible advice after all.
I have changed the blade profiles of about a dozen farrier's hoof knives to make them into better shapes for wood carving.
I use a Dremel and Dremel cutoff disks. Just take your time, little by little, so you don't cook it. Only have to do it once, right?
After market disks are thin, they wear fast and you really spend more, to get the same job done = crap.
1. Hearing protection.
2. Full face protection. A cutoff that explodes at 15,000 rpm really stings, every time.
3. Some sort of dust collection.
That profile can be smoothed out with the same Dremel and a stone.
Plus, the Dremel has many uses, unlike a stationary belt sander, as useful as they are.
I reduced the blade length of 2 original Germany army knives with a dremel (clone) a few years ago, First I placed the blade in a vice having wrapped the blade & GAK body with damp cloth to prevent loss of temper & to prevent sudden closure.
Both are UK legal and are daily carries by my son in law & myself.
I don't really see the point though, you can have SAKs that you have to have a reason to carry, and those you can carry freely. I have both, the locking version for when I can justify it, and the non locking less than 3 inch version for when I can't. No need to botch up a knife in either case.