How To Make A Knife To Be Proud Of From An Old Sawblade

 

HOW TO MAKE A SMALL SURVIVAL KNIFE BY HAND(1)

I’ve always wanted to learn how to make a knife myself to add to my growing collection,  maybe one day I’ll have enough. (One day)

Here’s how one knife maker, Trollsky, makes a field knife from and old circular saw blade.
One of the great things about steel is, its very recyclable and old saw blades can be made into all manner of tools and blades.

Yes, Trollskyy does have a knife making workshop setup, but many of the steps in the process can be improvised using hand tools and other methods. I don’t think you need a state of the art workshop to do basic knife making.

Give it a go – here’s how…

Step 1 – Find an old saw blade.

This one appears to be a bit of a monster from a sawmill.

1 - Find an old saw bladeVia Trollskyy on YouTube

Step 2 – Mark out and cut a rectangle shape from the saw blade using an angle grinder.

This will be the blank to start your knife design on.

2 - Mark out and cut a rectangle shapeVia Trollskyy on YouTube

Step 3 – Mark out the design of your knife on the blank piece of steel

The tang on this blade is full length for strength and durability.

3 - Mark out the design of your knifeVia Trollskyy on YouTube

Step 4 – Shape the blade and handle tang using a power grinder or bench sander.

You could use files if you don’t mind the extra grunt work and time!
Note the use of lots of safety gear – gloves and goggles as a minimum!

4 - Shape the blade and handle tangVia Trollskyy – YouTube

Step 5 – Grinding the blade edge.

One you have the shape of the blade done you can start to grind the edge. Trollskyy is using a finisher machine here but you could use an angle grinder or belt sander.
Be careful and make sure the metal is securely held or clamped down.

5 - Grinding the blade edgeVia Trollskyy and YouTube

Step 6 – Shaping the blade and tang done,

Starting to look like a real knife now.

6 - Shaping the blade and tang doneVia Trollskyy on YouTube

Step 7 – Drilling the holes for the handle pins

7 - Drilling the holes for the handle pinsVia Trollskyy on YouTube

Step 8 – Tempering and annealing the blade.

Annealing the blade is best done after the initial shaping of the blade stock as it makes the metal easier to work.
After the blade is finished it is heat treated and tempered so it will hold a good edge.

8 - Tempering and annealing the bladeVia Trollskyy on YouTube

Step 9 – Finishing the blade before moving onto fitting the handle.

It’s best to get the edge completely finished before moving on to fitting the handle scales.

9 - Finishing the blade before moving onto fitting the handleVia Trollskyy on YouTube

Step 10 – Wrap the blade in protective materials

To prevent damage to all the hard work so far when shaping the handle.

10 - Wrap the blade in protective materialsVia Trollskyy on YouTube

Step 11 – Mark and cut out the handle material.

This knife is set to have a couple of slick micarta composite scales. Stabilised wood, horn or bone are other materials commonly used.

11 - Mark and cut out the handle material.Via Trollskyy on YouTube

Step 12 – Cutting the Pins

These stop the scales moving during glueing and can be plain or decorative. A hole for a lanyard is also something useful to consider.

12 - Cutting the PinsVia Trollskyy on YouTube

Step 13 – Carefully drilling the holes in the handle scales one at a time so the holes line up perfectly.

13 - Carefully drilling the holesVia Trollskyy on YouTube

Step 14 – Clean all the handle surfaces thoroughly

Use solvent to remove the dirt and grease before applying epoxy glue and clamping tightly in a vice until the glue sets.

14 - Clean all the handle surfaces thoroughlyVia Trollskyy on YouTube

Step 15 – Use power sanders to grind the handle profile

Use strips of abrasive paper to get the final shape. You’ll use loads!

15 - Use power sanders to grind the handle profileVia Trollskyy on YouTube

Step 16 – Work through finer and finer grades of abrasives

Until you are satisfied with the shape and feel of the handle.

16 - Work through finer and finer gradesVia Trollskyy on YouTube

Step 17 – The finished knife

All its needs now is your makers mark and a leather sheath of the same quality to hold and protect it.

17 - The finished knife

One helluva knife maker
You can watch the full Trollsky video on you tube here –


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