Making a file knife, short tutorial

M

Matthew Bolk

Joined
May 19, 2010
Messages
17
Hello to all! I show you how I make my file knives, with little tools... Let's start with some old files, re-tempered in my kitchen oven, about 450 degrees, two cycles of 1 hour each:

jHv9eyC.jpg


I cut the file to lenght:

uNLlpyE.jpg


With my grinder and an expander wheel with a 40 grit zirconia belt, I shape freehand the profile of the blade (I have to frequently dip the blade in water):

kJA8hAs.jpg


The result:

evjCpuR.jpg


With a marker, I draw the edge. The tape will serve as a reference for grinding:

JEet7yS.jpg


For grinding the hardened steel, I use a 40 grit ceramic belt:

iJXDLtb.jpg


Water underside for prevent to inhale too much dust:

It4WZft.jpg


I fix the blade to a piece of wood, both for have a reference and for avoid to come near the belt with my fingers:

S06K2UP.jpg


UExBiHQ.jpg


Let's start grinding, it is important to make short strokes and dip the blade in water to keep it cool without compromising the temper:

sKw0Ijh.jpg


First side done:

aokIBmU.jpg


Then the other side:

fF94M75.jpg


Now the handle... a piece of black micarta and a piece of bois de rose:

4P4S49y.jpg


I drill freehand the guard and adjust the slot for the tang with a small rasp:

zkUGW1D.jpg


I shape the slot until it fits perfectly:

ul937D2.jpg


It fits:

49ojoZG.jpg


Then I drill the handle, just a bit wider than the size of the tang:

lpywtcq.jpg


I fix with epoxy both the guard and the handle, and I wait for complete catalysis:

bgnw3SY.jpg


When the glue is dry, I shape with a hand saw the handle:

QYg9Jxt.jpg


Then again on the wheel, I shape freehand the handle until it looks good, ending with some scoth brite wheels. This is the result:

sdCTyXs.jpg


iO0Pz9J.jpg


VWB4EJr.jpg


I know, it's not the perfect or the best way to make a knife, it's just a method to show everyone that it's possible to make a simple but effective knife with basic tools. I hope to inspire someone else to start this beautiful art! Thanks everybody! :);)
 
Nicely done. I appreciated seeing your approach. I plan to make some file knives myself in the near future, and I have limited equipment, so it was good to see how you tackled some of the issues.
 
I agree, nicely done indeed! :thumbup:

Just a quick tip: Make sure to grind back far enough from the tip area that you cut off using the angle grinder in order to get back to the properly tempered steel, as that section will have definitely been overheated for a few millimeters. (Though you may already be aware of that)

I remember about 4 or so years ago, I was searching allll over for those expanding (contact) wheels after seeing Ariel Salaverria using one in one of his picture tutorials on his site. I didn't have a grinder at the time, but I did have a bench grinder so I became a bit obsessed with figuring out what the heck they were called and where to buy them lol. I ended up finding them a couple years later, after I already had a grinder that is. ;) Sorry to get off topic, it just brought back that funny memory. I think it would be a great tool to have, especially if all you have is a bench grinder.

That handle turned out nicely as well, I really like the color that wood took. :)

~Paul
My YT Channel Lsubslimed
... (It's been quite a while since I've posted any new vids)
 
Last edited:
Good fun, and nice results!
Your improvised machinery is as impressive as that lovely handle.
 
Ah, file knives. So simple, but they look SO cool. :thumbup: Nice tutorial, it's amazing what you can do with a couple tools and a lot of mental ingenuity. :D
 
My first attempt at knife making was a file knife! I had to use a file a drill and a cutoff wheel but it was a fun experience for sure. I want to do another tho and see if I can make it look a little nicer than my first attempt. I also love the pics of your simple setup, fun to see your simple setup too...might have to steal some of your ideas for my own!

Matt
 
The Gopher said:
...so where do you get the expanding wheel?
Click to expand...

I mentioned in my post above that I spent a while looking but never ended up finding them until I didn't "need/want them anymore, as I had already built myself a grinder by the time I did find them.

Brownells sells them, here's the link:

http://www.brownells.com/gunsmith-t...ng-sanding-drums/sanding-drums-prod24604.aspx

Make sure to read the specs on each wheel (8" dia and 6" dia), as the 8" wheels needs a slower rpm than the 6" wheel. It's a little hard to tell from the pictures in the WIP, but I'm pretty sure Matthew has a the 6" wheel.

Hope that helps. :)

~Paul
My YT Channel Lsubslimed
... (It's been quite a while since I've posted any new vids)
 
Let me ask you this, though: Can you explain the heat treat process? I noticed that you tempered in the oven prior to grinding- does this take the place of having to heat treat the blade after grinding? I ask this because many other tutorials say to anneal, grind, heat treat, and temper. Thanks!!
 
Moosecaca, he kept the original file hardness, just lowering it a bit by tempering in order to have easier life grinding and to have a less brittle edge in the final knife.
If you need to hand file your file knife, than annealing and redoing the whole HT is on demand, but he grinded carefully with the ceramic belt and he did a good job.
Files comes with a very high hardness, an all around knife needs to be a bit softer than a file.
 
Repurposing, upscaling, recycling or what ever... nice work and a beautiful file knife!
rolf
 
Thank you all guys! My heat treating process is quite simple, I've learnt it in Wayne Goddard's book, and I think it is the same way knifemakers like Charlie Davis of Anza and Michael Morris also use (I'm great fan of their knives). You simply put your file (assumed it is a quality one, not case hardened) in the kitchen oven, and let them sit for 1 hour to 450-475 degrees, let them cool, then repeat another time. You should end with a file 58-60 Hrc or less, just the right hardness to make a knife from it. This is the key: when you grind, be extra-carefoul to not overheat the blade (I put it in water every stroke I make on the wheel). You end up with your hardened blade, no other heat-treating process required. If the blade is not too long and not intended to be abused, it's fine.
For the wheel, it's a pretty common tool among shoes makers, carpenters etc. Mine is a 8" diameter, 2" wide. Its main drawback is the short belt lenght coupled with the high speed it runs, which means it tends to heat up quickly the blade, so even more caution is in order, both for safety reason and to not ruin the temper of the knife.
 
You could also make a simple droplet system to wet your belt as you grind...the belts you are using will take water no problems, it doesn't need to be a lot of water to keep things cool and you will have more relax and be focused.
 
stezann said:
Moosecaca, he kept the original file hardness, just lowering it a bit by tempering in order to have easier life grinding and to have a less brittle edge in the final knife.
If you need to hand file your file knife, than annealing and redoing the whole HT is on demand, but he grinded carefully with the ceramic belt and he did a good job.
Files comes with a very high hardness, an all around knife needs to be a bit softer than a file.
Click to expand...

Matthew Bolk said:
Thank you all guys! My heat treating process is quite simple, I've learnt it in Wayne Goddard's book, and I think it is the same way knifemakers like Charlie Davis of Anza and Michael Morris also use (I'm great fan of their knives). You simply put your file (assumed it is a quality one, not case hardened) in the kitchen oven, and let them sit for 1 hour to 450-475 degrees, let them cool, then repeat another time. You should end with a file 58-60 Hrc or less, just the right hardness to make a knife from it. This is the key: when you grind, be extra-carefoul to not overheat the blade (I put it in water every stroke I make on the wheel). You end up with your hardened blade, no other heat-treating process required. If the blade is not too long and not intended to be abused, it's fine.
For the wheel, it's a pretty common tool among shoes makers, carpenters etc. Mine is a 8" diameter, 2" wide. Its main drawback is the short belt lenght coupled with the high speed it runs, which means it tends to heat up quickly the blade, so even more caution is in order, both for safety reason and to not ruin the temper of the knife.
Click to expand...

Thanks all for the info! I have some whitetail crowns in need of blades- this could be a fun project! Now- off to the thrift shops/swap meets to see what I can find!
 
Most farrier supply companies have the expander wheels. I have a 10" in my shoeing truck. They are crazy fast!
 
You must log in or register to reply here.
Back
Top