Making a knife from scratch can be fun, fulfilling and useful. It sure takes a lot of time and work, but if you follow these steps you will achieve the goal before you even know it.
Steps
Method 1 of 6: Draw the Blade
Step 1. Draw the blade
Use graph paper to draw the shape of the blade. Make it as realistic as possible to make it easier to make.
Be creative in designing the blade, but always keep in mind that it must be functional and practical
Step 2. Decide on the length
The length of the blade is at personal discretion; Long blades, however, are less manageable and require greater quantities of steel.
Step 3. Draw the shank
The tang is that piece of blade that fits into the handle. The simplest method is the so-called “solid tang”. The tang will therefore be of the same thickness as the blade, while the handle will be composed of two pieces of wood - one on each side - attached with rivets.
Method 2 of 6: Collect Tools and Materials
Step 1. Get some carbon steel
There are many various grades of steel. Do not use stainless steel, it is a difficult metal to work with and the blade will not come very thin. Conversely, 01 carbon steel is great to use, being very easy to cool.
Look for a thin sheet of steel that is 3-6mm thick
Step 2. Choose the material for the grip
Wood is pretty easy to work with, but you can make a handle using whatever you like. As this guide sees the presence of the solid tang, choose a material that can be attached with nails.
Step 3. Trace the edges of the blade
Using a permanent marker, trace the outline of the blade onto the piece of carbon steel. It will be the guide you will follow when it comes to cutting steel. Make sure you also draw the tang which, together with the blade, forms a single piece.
Once you see the silhouette on the metal, if the blade size doesn't suit you feel free to change it
Step 4. Retrieve the tools
You will need a hacksaw, angle grinder with hard wheel and flap disc, vise, drill, and protective clothing.
Method 3 of 6: Cutting the Steel
Step 1. Use the hacksaw to cut the metal
Cut a rectangle around the blade you drew to separate it from the excess steel. The thicker the slab, the stronger the hacksaw will need to be. Work the edges of this rectangle to get the outline of the blade.
Step 2. Smooth the profile
Put the piece of steel in a vice and scrape off the excess metal. Follow the lines you drew to form the outline of the blade. Use the grinder to finish the shape carefully.
Step 3. Smooth out the edges
With the flap disc of the grinder gently smooth the edges of the blade leaving the central body thicker. Make sure this slope doesn't go beyond the center of the blade. In this way the blade will begin to assume the right shape.
Be cautious during this step: sanding too much can ruin the blade, forcing you to start over
Step 4. Make holes for the nails
Use a drill whose tip is the same size as the rivets you intend to use. The holes must be on the tang. Depending on the size of the blade, you will need a different number of nails, and therefore of holes.
Step 5. Finish the blade
Smooth it out using fine grit sandpaper first, up to 220 grit. Take all the time you need to smooth out the various spots on the blade and fix any scratches. The better you work, the more brilliant and quality the result will be.
- Rub in opposite directions every time you change grain.
- You can use a file to add bumps near the handle. Draw a pattern and file away the metal.
Method 4 of 6: Heat Treatment of the Blade
Step 1. Prepare the forge
The best way to carry out heat treatment is by forging. For smaller blades, a blowtorch may also suffice. The forge can be powered by both coal and gas.
Also prepare a vessel for curing. To cool the knife, you will have to dip it while still hot in a container designed for this purpose. What you use depends on the type of steel, but for 01 you can use a bucket of motor oil. You will need to completely submerge the blade in the bucket
Step 2. Heat the blade
Heat it until the metal turns orange. Touch it to a magnet to see if it is hot enough (when the steel reaches the correct temperature, it loses its magnetic properties). If you see that there is no attraction, let the blade cool in the open air. Repeat the process three times.
- On the fourth time, instead of letting it cool in the open air, dip it in oil. Be careful, as a flame will form when you insert the blade into the oil, so make sure you have protective clothing.
- Once the blade has hardened, it can break during a fall, so handle the knife carefully.
Step 3. Heat the oven to 220 ° C
Place the blade on the middle surface and cook for an hour. After that hour, the heat treatment can be said to be finished.
Step 4. Sand again with sandpaper
Start again with a fine grit, work gradually until you use the 220 and also the 400. Sand the blade if you want a better shine.
Method 5 of 6: Attach the Handle
Step 1. Cut the handle components
In a full tang knife, there are two parts of the handle, one on each side. Cut and sand the two pieces at the same time to make sure they are both symmetrical.
Step 2. Attach the two parts with epoxy
Drill holes for the nails on each side. Do not get the resin blade dirty, it can be quite difficult to remove. Put the knife in the vise and let it dry overnight.
Step 3. Use a saw to make the finishing touches and modifications to the handle
Insert the rivets, leaving them protruding about 3mm on each side, and tap them with a ball hammer. Finally, sand the handle.
Method 6 of 6: Sharpen the Blade
Step 1. Prepare the whetstone
You will need a large stone for sharpening. Cover the rough side of the stone with a thin layer of oil.
Step 2. Hold the blade at a 20 ° angle to the surface of the stone you use to sharpen
Press the blade against the stone in a cutting motion. Lift the handle while moving the blade to sharpen well to the tip. After taking a few strokes, turn the blade to perform the same operation on the other side as well.
Once the edges have become sharp, repeat the sharpening on the thin side of the whetstone
Step 3. Test the knife
Hold a sheet of paper in your hand and cut it close to where you are holding it. A knife with a well-sharpened blade should be able to easily cut the paper into small pieces.
