My girlfriend and I stumbled upon some rigging/line splicing classes the the local large West Marine was giving about 7-8 months ago. While there we learned how to splice dyneema (Type 2 12 strand rope) and 3 strand nylon. I bought some cheap plastic fids. I was not a huge fan, but they worked and helped me learn. I read some where that knitting needles might work. I looked into that, and today I made 1/4″, 5/16″ and 3/8″ (6.5mm, 8mm, and 10mm) fids. You can get a 2 pack of the same size for under 3 dollars with a coupon at Jo-Ann’s fabrics.
I used a miter saw to cut a 52 degree cut into a piece of a 2×4. I’d go with 60 degrees if you can manage to get that cut, but my miter saw only went to 52.
I then drilled guides to slide the knitting needles into the jig so that i could cut the ends at the 52 degree cut. I used a vibrating multi-tool with a metal blade. I used the Samson sizes for the lengths of the fids, you can find that online.
Then swapped over the some 80grit sand paper on the multi-tool to make the edges not sharp.
I then marked the short fid length with wire cutters, though you cannot see the marks in the pictures.
Tools used for this project: Miter saw, drill, drill bits, vibrating multi-tool with metal blade and sanding pad and a scrape 2×4.