Making a dagger is not a simple thing, but with time, patience and attention to detail it is possible to do it. Choose the best materials, create a design that suits you and then cut out all the parts before putting them together.
Steps
Method 1 of 6: Choose the Materials
Step 1. Choose the most suitable steel
As a general rule you should get steel with a medium to high carbon content. One of the best options is 1095 steel, which is 1.27 millimeters thick.
- 1095 steel is quite inexpensive, easy to process and simple to work with.
- Another possibility to consider is L6 steel, which also contains a small addition of nickel. It is equally easy to handle, but it is a little less resistant.
- Other types of steel commonly used in the making of knives and daggers are 01 steel, W2 steel and D2 steel.
Step 2. Purchase a protective material
The "guard" is the strip of material that separates the blade from the handle. Brass is the best material for this purpose.
Try to get yourself a brass bar that measures approximately 2.5cm wide and 4.76mm thick. The length you will need depends on the size of your dagger, but typically you won't need more than about 14 centimeters
Step 3. Choose a good wood for the handle
Even though modern knives have plastic handles, you should focus on natural materials such as solid wood when making your dagger, to get a better design and an authentic effect. Solid wood is also easier for beginners to work with.
A good choice is amaranth wood. You can also try pomifera maclura wood, yew, eucalyptus, or manzanita
Step 4. Shrink and dry the wood
Wooden handles can shrink when exposed to heat and moisture, risking crack formation. One of the best ways to avoid this problem is to let the wood dry thoroughly before using it.
- In the summer, you can simply leave the wood in a car exposed to the sun for a week or two.
- Alternatively, you can set your oven on the lowest temperature and cook the wood for a few hours. Always keep an eye on it and remove it if you notice smoke or blackening.
Method 2 of 6: Design the Dagger
Step 1. Decide how long you want the blade to be
There is no "correct" length, so you will probably need to make an estimate to decide the length of your dagger. The first time you design a dagger you should think about a length of between 7, 6 and 10 centimeters.
- You can make a sketch of the blade first and measure it to get the exact dimensions, or you can decide the size first and then make the sketch. Both options are acceptable.
- Also consider the width. Theoretically, the blade width should be between 2.5 and 5 centimeters.
Step 2. Determine the length of the handle
The length of the handle should be determined according to the size of the blade and your hand.
- First, consider the size of your hand. The handle should be a little longer than the width of your hand, so that you can grasp and control it better.
- Then compare this measurement with the dimensions of the blade. The handle should never be longer than the blade, but neither should it be shorter than half of it. It should also be the same width as the blade at its widest point.
Step 3. Draw everything
Take your time to draw the dagger and clearly indicate all the measurements.
You can do the design by hand on paper or card, or you can also create the design on the computer first. Choose the method you feel most comfortable with
Method 3 of 6: Part Three: Cut the Blade
Step 1. Cut the steel
Use a hacksaw to cut a piece of steel as long as the sum of the handle and blade lengths.
Hold the steel in place with a vise as you cut it
Step 2. Place your design on top of the cut steel
Cut out the design you made earlier and lay it on top of the piece of steel. Carefully trace the contours of the design using a black marker.
Alternatively, you can temporarily glue the design to the piece of steel using a water-soluble adhesive
Step 3. Roughly cut out the general shape
Use the hacksaw to cut out the steel following the outline of the design; just remove the bulk of the excess metal.
- The idea is to get an approximate shape, it is not necessary to get the precise shape of the blade at this stage.
- Continue to hold the metal in place with the vise.
- Alternatively, you can also use an electric jigsaw for this step. Set the hacksaw to the highest speed and take frequent breaks to lubricate the blade with paraffin. If you don't lubricate the blade, it could overheat.
- The metal part that remains under the handle must be narrower than both the blade and the handle itself.
Step 4. Sand the metal
Refine the precise contours of the dagger using a metal file. At this time there is no need to sharpen the blade, but you will have to adjust it until you get the precise shape.
If you need more power than the metal file can offer, you can try using a belt sander or jewelry saw
Step 5. Smooth the blade
Secure the blade to the edge of the table using the vice and with the file adjust both edges so that they are evenly angled towards the center. The edges must be slanted on both the front and the back.
- Use a metal file to smooth the edges. The bevel should always be done by moving forward, never alternating forward and backward movements.
- Use both hands and try to apply as much force as possible.
- Keep the blade secured with the vice at waist height. This will make it easier for you to use all of your body weight in applying pressure and the procedure will not cause muscle pain.
- The ideal bevel angle is approximately 30 degrees. Try to keep this angle as constant as possible along the entire blade.
Method 4 of 6: Temper the Blade
Step 1. Start a fire
The easiest way to do this is to use a barbecue grill or garden fireplace.
- If using a grill, set a medium-sized block of briquettes on fire and air until they begin to turn red.
- If you are using a garden hearth, set fire to a medium-sized pile of wood mixed with charcoal briquettes and air over the flame until it gains strength and becomes stable.
Step 2. Put the blade in the fire
Take the metal from the side of the handle using pliers and insert the steel part that acts as a blade directly into the fire. Hold it in place, turning it from time to time, until the steel turns red.
- The steel must reach a temperature of around 800 degrees.
- You can use a magnet to check that ideal conditions have been achieved. When the metal is hot enough, the magnet should no longer be able to attract it.
- At this point the steel will be very brittle.
Step 3. Cool the blade
Immerse the blade in a container of high temperature resistant oil. Let it sit in the oil for several minutes.
- Hold the blade upright while it is submerged in the oil.
- Almost all types of oil are fine. Engine oil works very well, but you can also use vegetable oils and transmission fluids
Step 4. Heat the blade
Place the blade in an oven preheated to 200 degrees. Let it heat up for about 20 minutes.
With this process the metal is cooled, but the blade must be at a temperature between 175 and 290 degrees to harden properly
Step 5. Let the blade cool
When you notice that the blade has turned a yellowish color, it means that the metal has hardened properly. Let it cool down to room temperature by storing it in a safe place.
Method 5 of 6: Making the Handle
Step 1. Make holes in the part of the metal that will be part of the handle
Use a drill press to make two holes in the metal that will allow you to attach the blade to the handle.
- The holes should be placed along the central horizontal line of the blade. Keep a space of at least 5 centimeters between them.
- Each hole should be 6.35mm in diameter.
Step 2. Cut out the two halves of the handle
Place the dagger design on top of the piece of wood and trace the outline of the handle with a pencil. Repeat this one more time to get two separate pieces and use a hacksaw to cut them out.
When you've cut them out, the two pieces should be a little longer and a little wider than the handle you want
Method 6 of 6: Part Six: Putting the Whole Together
Step 1. Cut out the brass guard
Place the brass bar on the dagger, placing it between the blade and the lower part that will then be covered by the handle. Determine how long you want the guard to be, then trim the bar to the chosen length.
- There is no need to shape the guard after clipping it.
- Use a hand or electric jigsaw to cut brass. Hold it steady using a vise as you cut it.
Step 2. Make a slot in the guard
You will need to drill holes and then widen them with a file in the direction of the length of the metal guard; the slot must be large enough to just pass the blade.
- Using a pillar drill or power drill, make five small holes aligned along the center line of the guard. This series of holes should be no longer than the width of the blade.
- Use a metal file to remove the material between the holes. The slot thus obtained must not be wider than the thickness of the blade.
- Make sure the slot is wide enough to fit into the metal part that will act as the handle, but not wide enough to slide across the blade.
Step 3. Make holes in one of the handle pieces
Insert the brass guard into the dagger and place it in place, then pin one of the wooden pieces of the handle along the corresponding metal part. Use an electric drill to make holes in the metal so that they also go through the wood.
Make sure the handle and blade are perfectly aligned. If they are not precisely aligned, the holes in the handle will be in the wrong position
Step 4. Make holes in the second piece of the handle
Place the second piece of wood of the handle on the other side of the metal piece and hold everything in place with the vise. Make two holes in this piece of handle, extending the holes already made in the other piece of wood and in the metal.
Step 5. Cut two brass dowels
The dowels should be about 6.3mm wide and long enough to fit through the series of holes along the handle.
It is better to make blocks that are too long rather than too short. If they seem too long, just file the excess so that, once inserted into the handle, they are perfectly level with the wood on both sides
Step 6. Glue the two pieces of the handle together
Mix strong epoxy resin and apply it liberally to the inside of both halves of the wooden handle. Place the two pieces on the dagger in their respective positions.
Do not let the epoxy dry
Step 7. Insert the dowels with a hammer
Put a dowel in each hole and use a hammer to push them into place.
- Once the plugs are in place, remove excess glue using white spirit.
- Hold the dagger with a vise and let the resin set. The vise must not press on the anchors, as they could deform as the resin dries.
Step 8. Refine the dagger
Use sandpaper to refine the blade until it becomes shiny.
- You may need to hold the dagger in a vise while polishing the blade.
- Use different types of sandpaper, starting with a lower grit (200 for a start), progressively working up to a higher grit (1200).
- This step completes the entire procedure.
