WIP: first knife, all hand tools

D

DirtyBrad

Joined
Dec 20, 2006
Messages
79
Started looking for a replacement for my Gerber LMF and couldn't find anything that was exactly right. Then I stumbled on this forum. You know the rest...

Trying to get this done for a five day trip on the river this December. I'm trying to do everything myself. Stock removal with just hand tools. No power until I do the heat treat -- I've got access to a kiln for that. I'm going to make my own micarta for the handle and do a kydex sheath.

Steel is annealed 1095 from Jantz, 3/16" by 2" wide. Blade length is 5", overall is about 11".

Anyway, onto the pics. Just a couple so far.

The design drawn and traced onto the steel. Blue lines are the saw cuts.

1.JPG


Sawing done, ready for filing.

2.JPG


Many, many thanks to this excellent forum. You guys have already been a huge help and I'm sure I'll be asking a million more questions. Also, seeing everyone's galleries has been a huge inspiration (maybe a little theft, too). I'll keep the pictures coming as I work.
 
good on ya! Good luck!
 
Nice design. Man that must've taken a while to saw all those pieces.
I look forward to seeing more.
 
Thanks, guys.

Wasn't too bad. The high-tension saw does a good job and the annealed 1095 seems pretty soft.

Probably three hours tonight while watching basketball and stopping for Chinese in the middle.

I'm hoping to get the outline filed down tomorrow, the blade beveled Saturday, and polished up for heat treating Sunday.
 
It would seem we are both doing the same thing at the same time... First knives the hard way.

Definitly tagging for your progress.
 
Excellent! Got some pictures or details?

The only thing I'm really nervous about is the heat treating.
 
Looks great, very nice work.

I was looking for some 1080 the other day for the easier heat treat, but couldn't find it wide enough.
 
DirtyBrad said:
Looks great, very nice work.

I was looking for some 1080 the other day for the easier heat treat, but couldn't find it wide enough.
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I was directed to Kelly Cupples Steel. If you google it, it should be the first result. He was local so I didn't pay shipping, but he quoted me a peice of 1080 bar stock 3/16 x 1 1/2 x 4feet as 15.50 + 10.50 shipping.

If that helps for future projects :thumbup:
 
Don't tell my girlfriend there will be future projects.

I did see his site. I'm using 2" wide right now and it's just barely enough for this one. The usable width winds up being a little less because the edges are very slightly rolled.

My original design had a thumb stop on the top, but I didn't have room. I've been looking for a piece that's wider, but haven't been totally satisfied. Admiral has it, but not annealed. When I screwed up my first try at this, I ordered that, figuring I could just do it myself, but then ended up canceling and taking another crack at this piece. I'm trying to keep the first one as low-budget as possible.

McMaster also had some very wide 1095, but I'm not sure what condition that ships in. I think the smallest piece they had was $50 before shipping so I didn't want to chance it.

How's that 1080 to saw? I was pleasantly surprised with this. I've worked with small aluminum stuff before. Cutting that with a very small saw and this with a very large one feel about the same to me.

If the 1080's about the same to work with and I can find a piece that's wide enough, I'd definitely jump on that. I'm real nervous about the heat treat on this. It would be nice to be able to use vegetable oil or something and be able to take a little more time.
 
This is a tough one to nail down. Before I started this, I put up a thread asking if it was stupid to try to do this type of knife by hand. I got back the whole spectrum from piece of cake to it's a pain in the ass.

I think you said that it took you about three hours for one part of yours, but that it was enjoyable time. I definitely related to that. Doing the sawing took me the same amount of time. My hands were pretty cramped and I was sweaty, but it was a good time.
 
DirtyBrad said:
This is a tough one to nail down. Before I started this, I put up a thread asking if it was stupid to try to do this type of knife by hand. I got back the whole spectrum from piece of cake to it's a pain in the ass.

I think you said that it took you about three hours for one part of yours, but that it was enjoyable time. I definitely related to that. Doing the sawing took me the same amount of time. My hands were pretty cramped and I was sweaty, but it was a good time.
Click to expand...

Yeah. I am up to about 7 hours of work. Most of it done with a tv on in front of me, so not always exactly 100% work. But it isn't work that I mind doing, it isn't tough... Just slow. If the knife turns out anything like what I have in my mind I think it will be more then worth the time. Not like I am doing much else with that time anyways.
 
Handle done, working on the blade. I found it easier (or at least not as boring) to do a row with the round before hitting it with the flat:

4.JPG


All cut out. Flats are finished with 100 grit paper:

5.JPG


Edges are finished with 220:

6.JPG


I'm extremely happy with how well the handle came out. 100 and 220 grit wrapped around a Rock Band drumstick does a nice job:

7.JPG


I'm really happy with the top here. On the last try, I had to round the corner, but I was determined to get it right:

8.JPG


I didn't sand the blade edge since it's going to be mostly filed away when I bevel:

9.JPG
 
Amazing, especially for a first time, i got a similar project, using hand tools. Looking forward for updates on this.
 
Thanks, man. Next update's going to be tomorrow, but it's going to be another start. I've been reading and reading about the steel and I'm just not feeling good about heat-treating the 1095.

I ordered some 0-1 instead, which arrives tomorrow. The design is going to be virtually identical, but I'm going to lengthen the blade slightly and make the choil a little shallower
 
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