Hello Genitalmen... here's the plan.
1. Start with a knife. Probably one of mine... unless Andy wants to donate one for the team... Ha!
2. Dehandlenate it. (Try to keep up with the technical terms, K?)
3. Try to forge that baby down to a respectable file size. Obviously, I can't make a 14" mill bastard, unless I start with a 3 foot sabre but this ain't gonna be a nail file either, boys. I'm going to hammer the bevels and tip back into the center mass of the blade. The process is called "upsetting". (the tip might be really hard to do, but I'll try).
4. Clean up the surface all nice n shiney like.
5. Hand sew the file teeth, using a chisel/punch. I will also be making this tool. I would like to try my hand at making both a steel file and a wood rasp... 1/2 and 1/2
6. Heat treat the file and run it through a temper cycle.
7. Test the newly made "Knifile" on wood first... then steel
I have never EVER made a file and do not know much about it so this will be a learning experience for me. I will be making this up as I go. Hand making files/rasps is an art that takes many years to become proficient at. I will stumble into this with the utmost respect for the folks who do this for a living... I DO NOT CLAIM THIS WILL BE SUCCESSFUL, NOR DO I CLAIM TO BE A FILE MAKER. Though, I DID once stay at a Holiday Inn Express.:thumbup:
I'm trying to see if I can get Ken(kgd) to document this with video and pics but schedules are tight. If we want to do this right, it may have to wait until after the holidays. Trying to fumble with a camera while making this thing might not work so well for me.... niether would having two housemonkeys all hopped up on Christmas bon-bons trying to get into the shot while I'm flailing about with hot steel and a hammer.
Rick