Files, Hacksaw, Sandpaper, and an Electric Drill

M

me2

Joined
Oct 11, 2003
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Anyone make knives this way from stock? Since I have a blistering production rate of about 1 knife/year, it won't slow me down any, and may lead to some understanding and insight. I'm almost out of prehardened M2, and have switched to new A2 PG stock.
 
I made my first knife like this, but not from pre-hardened stock. It was a real bear with annealed O1, I don't even want to know how long it will take with pre-hardened steel... My thumbs hurt just thinking about it.
 
I'm with you on the file and sandpaper. However, It would really be worth you while to buy a 25 dollar angle grinder and some 2 dollar cutoff wheels. it makes life so much easier. as far as the electric drill goes, how have you been able to get the holes straight?
 
Some people do, but I'm simply not that patient.

I would at least pick up a cheap belt grinder.
 
I only make knives in the spring, summer and autumn so I have annual knife-making seasons. I made five knives my very first season (2008) with files, sandpaper and drillpress, and started out the 2009 season the same way until I tried using my hand-held belt sander (3x24 maybe?) to grind the bevels. Half way into the third knife with the sander and it started to make all sorts of grinding noise and not work. It caused me heart problems. I just didn't have the heart to go back to using files again and started looking for a replacement sander. After a week of looking and thinking I bought a Sears 2x42 belt grinder. It runs way to fast and is far from ideal but it was what I felt I could afford.

I think if you were to use some sort of belt sander/grinder you could conceivably increase your annual production by 100%!!!!

If all the belt grinders in the world just disappeared I think I would grind blades by sticking my hand out the car door while driving and grind against the pavement. Patience is not my strong point, and also the reason I'll never make the flawless knives I see on this forum.

- Paul Meske, Wisconsin
 
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Untill I modefy my grinder to a usefull machine I file and sandpaper my knives.
A dremel is a good thing to have. Once you have it you'll use it more and more.
(buy cut off wheels and sanding drums from eb@y they're a lot cheaper there)
 
I've been working that way. I've had four failures so far, two abandoned and two broke during heat treat. I have an angle grinder and three belt grinders, a 6 x 48, a 4 x 36 and a 1 x 30 but they're all to fast and agressive for me as a beginner.

I'm normally patient but I'm running out of patience and I'm ready to learn to grind the bevels on the 1 x 30 even if it is so fast and agressive. If I get some appropriate belts for the 6 x 48 I can use that for the tang and Ricasso but I run the risk of rounded edges and corners because of the high belt speed.

To make a long story short, my hands and arms are getting tired but my filing and sanding skills have greatly improved.
 
I invested in a bubble jig this spring and using it has improved my flat grinds a LOT. It doesn't hold the blade for you, but it tells you when you're holding it at the correct angle. There are still many ways to screw up a grind. I could see an improvement in the first blade I used it with, but it took about three blades under my belt before I felt I was getting the hang of it. My grinds are higher up the side of the blade than I thought I was capable of and they're EVEN (ish)!!!!

I use a Sears 2x42. It runs at the speed of light and is far from ideal but it's what I have.

- Paul Meske
 
The prehardened M2 cuts my files if I try them with a file. I have a small cheap belt sander I use for sharpening, and actually made 2 knives with it from bar stock. I actually want to try it this way, and was looking for advice or tips. I'm of the opinion that most knives available today for general use are too thick, so I'm planning on sticking with 3/32" thick and under. My A2 supply is 1/16". I'll just start and see how it goes. It's not like I'll make quick progress and be done before all the advice comes in.
 
I think you may be amazed at just how many people here started with some files, sand paper, hacksaw, and a drill. If you have the patience and the time you can make a very nice knife that way. Its after we have made a bunch and realize how much fun it is that we make the step to buy a grinder and all the other goodies
 
man im glad im not the only one roundin my edges.

i just spent 2 hrs today hand filing 3/4 of my edge to match the other side and i got to carried away and now i gotta file the other side all over again

im on my 1st knife and im already flustered with hand filing but i wanna stick to a more primitive method

but i think i want to upgrade so i can make more then 1 knife every 3 months, how are the free instructions for making belt sanders out there?


ooo
 
Made quite a few knives out of 01, files, hack saw, drill and sand paper. Oh yeah, can't forget the one brick forge and propane torch.

Power tools help me make knives faster, but they can help me mess them up faster too!
 
I'm working on my first right now and using nothing but files to shape it still got a long ways to go. Some reason I find it very relaxing.
 
Bojtos is definitely one of the best, power tools or not. This guy ain't so bad either; http://www.wolfeknives.com/
I've made 3 1/2 knives, (one of those was a Ray Richard forged out blank, hence the 1/2) all with hand tools and a drill press.
It's good times
 
I never end up being happy with a dremel. just not fun to use.

I would really recommend cutoff wheels on an angle grinder. and a drill press- any drille press, cheap, small, whatever. handheld drills want to go too fast.

I'm not sure I'd really enjoy wearing down files trying to make a 1/4 inch spined flat grind, but I've done a few knives with nothing but the files and paper. SMALL ones, and THIN ones.

Aside from the hacksaw (granted, I have 4 in my shop, all GOOD ones), it sounds like a fine setup for taking your time.
 
All Of my knives were made either dremel or drill out the profile, then either 4x36" grinder or files and sandpaper. If you want to do it the tools wont stop you. Go and develop your style. I will get a real grinder some day though.
 
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