Phillip Patton knife, progression thread

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Keith Montgomery

Keith Montgomery

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Phillip Patton is making me a forged chute knife from D2. Here are some early photos.

The first two are of the block that the blade was forged from. It is 1 3/8" X 1 3/8" X 5".

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Next is the block with a handle welded on. Regular welding rod doesn't work well on D2, so phillip used stainless rod.

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Here it is after about 5 "heats". An air hammer was used to draw it out, otherwise Phillip would still be at it.

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Starting to shape the tip.

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About half way there. All the shaping was done via hand hammer, except a little on the butt end.

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Phillip used a hot chisel to cut the blade fom the parent stock. With simple steels he usually uses the oxy/acetylene torch for this operation, but that doesn't work well with high alloy steels like D2.

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Here it is cut off, and shown next to the pattern. As you can see, it's too short. That's because Phillip will be using the power hammer to forge in the tang taper.

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There almost wasn't enough material. :eek:

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both hand and power hammers were used to forge in the dropped part of the butt.

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This pic came out fuzzy, but you can still see the taper somewhat.

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The blade was put in foil wrap with a tissue paper, and Phillip programmed the oven to run an annealing cycle, which for D2 goes like this: Hold at 1600 F for 2 hours, then cool at a rate of 25 degrees per hour to 1000 F, then air cool.

More to come.
 
It's always a treat when you can see YOUR knife being made. A treat for the rest of us as well.

Roger
 
The chute knife is my absolute favorite all-time pattern. I can't wait to see the progress on this one.
 
This is the first time I see the forged D2.

THANKS for sharing. :thumbup: :D :thumbup:
 
I've been thinking of getting a forged D2 knife for some time! You beat me in asking Phillip to make one Keith! Congratulations! And thanks a lot for sharing :thumbup: :D
 
mohd said:
I've been thinking of getting a forged D2 knife for some time! You beat me in asking Phillip to make one Keith! Congratulations! And thanks a lot for sharing :thumbup: :D
Click to expand...

Immediately on seeing that Phillip forged D2, I contacted him and placed an order. D2 isn't a stainless steel, but it is close, and makes for a much better choice than carbon steel for a full tang knife.
 
Love these threads... as mentioned above. Plus I really like Phillips work.

Looking forward to more progress pics. It's great to see your knife actually got thru the creative processes to completion.
 
Phillip didn't have the right size grinding wheel, so he had to order one. It is going to take a couple of weeks to come in. He will be doing some other work on the knife and sending me more photos soon.
 
Here is some more images.

In this picture, Phillip used a 4" angle grinder to remove the forging scale from the surface of the blade.

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Here he's drawn the outline of the knife on the forged blank.

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In this photo he's ground down to the line using the belt grinder.

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In this one he's started flattening the tang with the disc sander.

flatteningtang.JPG
 
I guess it will be a 5 1/2" Blade and 11" OAL knife. I am curious about the blade thickness at the spine. Mine which is made by Phillip has a 3/16" thick spine at the point about 2 1/2" at the front of the ricasso. And it has a distal tapered spine from that point to the tip and as well as from that point to the butt. Meaning the thickest part of the spine is not at the ricasso. And I like it very much that way :thumbup: I just wondering whether Phillip builds all his knives the same way as he built my knife. Care to check it please Keith.
 
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