How I spent my vacation....my 1st folder

Joined
Mar 27, 2001
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I'm still pretty new to this knife making thing...but I really wanted to make a folder. This is my 1st attempt. The blade is O-1 tool steel and the handles are 6061 aluminum, the liner is .040 stainless. The blade is parkerized (I've had some experience with that), and the handles are anodized (I haven't had experience with that.. but I'm learning). The blade is 2-3/4", O.A.L. is 6-7/8. I know...the thumb stud is missing :(....I forgot to order one, it will be added later.

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I'm going to redo the anodizing, it was supposed to be much darker. I used steel alligator clips to hold the pieces and they dissolved before the process was complete and the aluminum wouldn't absorb much dye. It was very challenging and rewarding to make. I really need to work on my grinding technique, the way I chose to do the blade was really beyond my present ability to do well. Fortunately, parkerizing is a very forgiving finish :).

A couple of thoughts for any new makers like me considering making a folder:
1) Buy and read Bob Terzoula's book "The Tactical Folding Knife".
2) Read it again.
3) Take you time making a pattern and try to work out as many problems as you can with the pattern, it will save you many headaches later on. I'll spend more time on mine next time.
4) I had never drilled and tapped small holes before, 1-72, I have a couple of import sets of number drills, and they are not all the same size for any given number. Try your drill/tap combination on a piece of scrap to see what works best for you. I recently picked up a small hand tapping machine...highly recommended.
5) I couldn't make accurate enough holes with my HF drill press, although I had excellent results using the Grizzly mini mill.
6) If you try anodizing aluminum at home and use a suluric acid solution, don't rely on the formula commonly available. Buy a hydrometer (battery tester, $3 at auto parts store) and mix for a specific gravity of 1.5 to 1.8 (did I mention not to use steel clips? use aluminum wire). Mix small quantities in a small container placed in a larger container filled with cold water to keep the mixture cool. (thought I was going to melt the bucket for a while :eek: )

Patrick
 
Good looking folder! Seems like you got a lot out of your first one. Thanks for the tips on anodizing aluminum. How are you planning to attach the thumb stud?
 
Andrew

I'm going to try drilling a hole with a small carbide drill and attach using a button head torx screw, there should be enough clearance on the other side for the head. I dont want to try countersinking a flathead screw at this point. Not ideal, but better than nothing.

Thanks for the nice comments guys :) :) :)

Patrick
 
Outstanding Patrick!!!! The bevels you put on the handles are what I've been trying to figure out how to do for ages. How do you do it and keep them so even?? Gorgeous knife!!!
 
It's hard to see, but that's a really nice grind! Great knife, one of these days I'll grow the huevos to try that too... Thanks for raising the bar! :D
 
The bevels are really easy. I use a router bolted to 12" X 12" X 3/8" piece of aluminum that is in turn clamped to my drill press table. It's very sturdy and adjustable for height.

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The router bit is a carbide (a must!) 45 degree chamfer bit with a ball bearing guide. The handles were too thin to do individually, so I screwed them together and the top piece rested on the bearing surface and acted as a guide for cutting the bottom piece. I put masking tape on the handles to protect them from scratches on the table. You just move the edge around holding it firmly to the bearing surface feeding the work into the direction of the cutter rotation. After that I hand sanded to 320 grit and bead blasted. I've used this on wood, aluminum, brass, and nickle silver. Wouldn't try it on stainless, carbon steel or Ti.

I make test cuts on scraps of MDF to make sure the depth is correct before cutting anything important.

It looks a little scary having the bit up there with no guard, but I used to be a carpenter and am sort of used to working with handheld power tools with no guards. I'm still very careful though;)
 
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