Tcvi. Just for you:
For the piece of steel to use for the blade. I cut that out with cut off wheels and a dremmel. Use your bare hand to hold it as you cut so you can feel when it gets warm as I said before. These wheels can be bought in a kit or a 10 pack at Lowes and I think Sears sells them also. I use the stone type for this as they are thin and produce very little heat but they cut well and fast. Just take your time and let the wheel do the work. You'll need about three to do a cut like I did off the donar blade for my push knife.
Then go to a scribe or pencil and trace out the pattern you made onto the steel.
Once you are satisfied with that go to a bench grinder and don't forget to take along your cup of cold water. Grind out the shape there using the bench grinder keeping the blade cool by frequent dipping.
Once you have your shape out you need to take off the burr from around the edge. The same cut off wheels work well for this so go back to the dremmel.
On a blade this small I use my DeWalt variable speed electric drill mounted on a Sears Craftsman Lathe. These are cheap to obtain and they actually work but I rarely use the lathe. I do however you the drill for various tasks all the time.
I used a 1.5" sanding drum with med grit to start the hollow grind on these push knife projects. Then finished grinding with a fine and eventually moved to a fine that was well used so it made the grind lines even smoother.
If your drill is one that is variable speed but only has the lock for a high speed steady rpm get you one of those quick clamps in the small size at Lowes and you can squeeze it in on the button to make the drill rpms go any speed you want. Just keep the cup of water handy and dip often. With the drill set up being reversible you can always grind so the wheel is spinning away from the edge. Just reverse the direction when you flip the blade.
I make one of these push knives in about an hour start to finish but I've probably done into the teens of them. I think the first one I did was an all morning project to get all my ducks in a row. I think its a lot of fun and you make use of something that is someone elses trash which kind of turns me on.
I get these sidewalk edger blades free at the local Rental Service Center. The guys that work there are all carrying a knife I made them using these old recycled blades. They save them for me every summer now. I must have about 6 so far this summer. Total cost in a project like this is for the sanding drums and the cut off wheels, electric power which is pennies, and labor which is hard to calculate.
The elk antler handle came free also from a natural dropping found in the woods. I use my band saw to cut a slab and my belt sander to grind it flat. 3/32 pins came from Lowes and are brass. I stictched a leather case for it also but rather like the one I made from the antler better. It is more unique.
But most people prefer the little leather ones I make. I get scraps for just a few bucks at a local saddle shop. For $10 I can get about a years worth of knife sheath supplies. Being the consumate back yard mechanic that I am I have found pretty cheap ways to feed my hobby and knife/cutlery addiction/passion by whatever means necessary.
