I am using a couple of methods... I am using a hacksaw to cut out the profile. I tried an electric jigsaw but it just insta-destructs the blades. I am going to run by Home Depot today and get the best blades I can and see if they work.. what I have now was a metal cutting blade in a 5 piece multi-pack that was $2.99. If that works, well and good.. if not I am going to drill holes all around the perimiter and "connect the dots". A dremel sounds interesting too, but I would have to wait for cash flow to improve.
Then, even up the cut with a bench grinder or 6" disk/4"X36" belt sander to get a smooth outline.
Mark edge centerline and bevel limits and start filing away. My plan of attack is to file the plunge cut first, then use a draw file method from the area by the plunge to the tip and try to match the draw filing to the straight filing at the plunge.
Then, I move to smoother files, and finally finish files.
Grind the flats and bevels on a big coarse wetstone, then the finer wetstone side.
Move on to a 180 grit belt, then 220, 320. Then I send it to Paul.
Clean up after heat treat w/320-400 Grit on the belt being careful not to overheat.
Hand sand from 500, 800, 1200 then polish on my buffing wheel.
Drill, fit and pin dovetailed bolsters.
Ohhhh... this brings me to another dumb question... do I have to make and drill my bolsters prior to heat treat? Do I pin them in before or after heat treat? In other words, can (And should) the blade be heat treated with the bolsters already on? Normally I think you do this after, but will a commercial heat treater usually harden an entire stainless blade, meaning the tang area will be hardened also?
Match the wood to the dovetail on the bolsters (IE, same angle on disk sander), drill then epoxy and pin. Shape handle to suit, seal and sand to 1200 grit then polish that. Another silly question, do you use different compunds when polishing the wood handles?
Then I take pictures and post them here so everyone else will know how NOT to make thier first knife...
Wow, that ended up quite the long post... if I am missing anything let me know.
