How do i remove serrations/reshape a blade?

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Jan 7, 2006
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my old Gerber EZ-Out beater knife is just that, a beater, i've broken the tip off (a freind reprofiled and resharpened the blade) and it's handled my "learn how to sharpen" abuse well, it's been a good, reliable freind for a long time

i'm beginning to realise that i don't really like partially serrated knives, i'm more of a plain edge fan, so i got to thinking.......

what would be the best way to remove/grind off the serrations on the EZ-Out and reprofile the blade (i'm thinking more of a "hawkbill-ish" style blade), is it as simple as getting an extra coarse hone for my Lansky and grinding the serrations away then reshaping/resharpening the blade?

there's a electric grinder in the attic with a stone wheel and wire wheel, it looks far too aggressive to use to reshape the edge, i can see it ruining the tempering on the blade, maybe even chewing a gouge in the blade....

so, what's the safest and most effective way to remove serrations?
 
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Sep 28, 2005
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Any method will work as long as you do not forget the cardinal rule----DO NOT OVERHEAT THE BLADE!!! If using the Lansky I would suggest a diamond stone as it will cut much faster. You could use the grinder to hog out much of the serrations but stop before creating the actual bevels and continue by hand as then the worry about gouges would be lessened.
Post some pics when you are through- the EZ Out was my first beater too!
 
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Jan 7, 2006
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so, you're saying i *could* use the grinder? just use light pressure to "sand" away the serrations, correct?

then i'd re-profile with the Lansky and finish up with the Sharpmaker?
 
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Well, that was quicker than i thought....

i decided to take a chance with the old Gerb... after all, it's a beater, i don't care if i ruin it....

i think i did pretty well for my *first* reprofile job, this is the first knife i've ever fixed, it was pretty easy too, fire up the grinder, and hold the knife straight up and down against the wheel, use short passes and let the blade cool between restructuring passes....

Before;
Gerber.jpg


After;
Gerberfixed.jpg

Gerberfixed2.jpg

Gerberfixed3.jpg

Gerberfixed4.jpg
 
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honestly, i have no idea if it got too hot, it never got too hot to touch, i'd imagine the darkish patch above the edge was just where the blade coating got worn away, it has this gray coating stuff on the blade, that's what's darkened

i did the full reprofile with the Lansky, from coarse to ultrafine, then finished it up on both rods in the Sharpmaker, this thing is shaving sharp now, i've actually gotten a couple of dermal cuts from it, no blood, but it can shave away small sections of epidermis, and it trims callouses really well, the edge sharpness is right up there with my Spydies...
 
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MacTech, you do realize this is just the start of a real addiction.:) I can remember my "first" and you know they say; you always remember your first!:thumbup:
 
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Mar 29, 2005
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EZ Out was my first real user as well. Not bad for your first time. It looks pretty cool actually.
 
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wwells20 said:
MacTech, you do realize this is just the start of a real addiction.:) I can remember my "first" and you know they say; you always remember your first!:thumbup:

Heh, you weren't kidding, i'm actually playing around in Photoshop trying out different ideas on further blade-chops, maybe putting a more extreme curve on the underside, maybe chopping the top, just playin' really, if any of my photochops look interesting, i may post them in this thread....

by the time i'm finished, the ol' Gerber won't look *anything* like it was in the beginning....
 
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wwells20 said:
MacTech, you do realize this is just the start of a real addiction.:) I can remember my "first" and you know they say; you always remember your first!:thumbup:

Heh, you weren't kidding, i'm actually playing around in Photoshop trying out different ideas on further blade-chops, maybe putting a more extreme curve on the underside, maybe chopping the top, just playin' really, if any of my photochops look interesting, i may post them in this thread....

by the time i'm finished, the ol' Gerber won't look *anything* like it was in the beginning....

some quick-n-dirty photoshop jobs;
Gerberchop.jpg

Gerberchop2.jpg

Gerberchop3.jpg
 
Joined
Jan 12, 2006
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I had that exact same knife, did the exact same thing. Mine has less recurve but you can still see two spots in the rear just above the cuting edge from the serations. The thing was perfect and saw much service but the handle is starting to crack. Just replaced it with a CRKT M21-04. The blade is perfect except that it said tiwain on it till I polished it off, and I'm sure someone will act like I brought a sword to work. But am already toying with the idea of making my own lock out of slightly thicker steel, or at least have it thicker were it makes contact with the blade. Although it shows no signs of trouble as is, but I got to mess with everything. If it's not modified, it's not mine.
 
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Dec 31, 2004
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MacTech said:
Heh, you weren't kidding, i'm actually playing around in Photoshop trying out different ideas on further blade-chops, maybe putting a more extreme curve on the underside, maybe chopping the top, just playin' really, if any of my photochops look interesting, i may post them in this thread....

by the time i'm finished, the ol' Gerber won't look *anything* like it was in the beginning....

some quick-n-dirty photoshop jobs;
Gerberchop.jpg

Gerberchop2.jpg

Gerberchop3.jpg

I not good with pics, but I will try to post some of my work. I have a pic of a Para-Mili I "chopped down" floating around here somewhere. I'll try to find it.
 
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Jun 25, 2002
Messages
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Man that first pic looks like a commander, nice work. The ezout was my first beater also, then lock failed and cut me pretty good right across my fingers that was the end of that!
 
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Sep 28, 2005
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I love what you did to the knife- always nice to see a knife given a new life- much better than just retiring it
 
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