Instructables
Picture of Add Serrations to a Pocket Knife
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After buying this pocket knife I found out it's also sold serrated. Instead of returning it I added the serrations myself. For doing it by hand I think it turned out well. All you need is a dremel tool, or something similar, and some diamond bits. 
 
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Step 1: Mark out your pattern

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Start out by marking where the center or each serration will be. Make sure to extend the mark just a little past the bevel of the blade. I did one mark every 1/8".

Step 2: Cut in guides

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These little grooves will serve as guides for the next step. Using a diamond blade I cut into the blade just up to the edge of the bevel. 

Step 3: Shape the Serrations

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These diamond bits can be found through Harbor Freight for around $7 a set. Start with the smallest bit. Grind away while holding the knife at a steep angle. Move your way up to the largest bit. While you're doing this check often to make sure your grinding is centered with the guiding groove.

Each groove will eventually disappear. Once you can no longer see them, your guide changes to the shape of the serrations. Gently put pressure towards each tooth until you have a uniform pattern.  

Step 4: Clean up the backside

This side has less aggressive channels. During this process burs are forming on the backside. This step is for getting rid of them. Repeat the same process except with just enough grinding to remove them. I used the medium sized bit here.  
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Great Instructable!

Seaborn3 months ago
Which model is it?
vladivastok5 months ago

WANNA DO THAT. NEEDED A NEW DREMEL ANYWAY. THANKS [VLAD]

dsherman17 months ago
I think I will apply your method to one of my knives
marcellahella8 months ago
Cool instructables! I imagine this is also a good way to sharpen serration that are already there…I was wondering how to do it myself.
jlee1639 months ago
Gerber knife I have that knife it's great
Lt.Greg10 months ago
Thanks. I didn't see that many derogatory comments - but then I didn't read them all. And you're absolutely right about a hot knife only working on synthetic rope. Sounds like you maybe know what you're talking about. :-)
G
baudeagle11 months ago
I liked how you use the abrasive blade to start the serration process, I imagine this works great.

Another Idea would be to use a triangle file to add the serration. Here is an example.

https://www.dlsweb.rmit.edu.au/toolbox/electrotech/toolbox1204/resources/03workshop/05hand_tools/images/triangle_file.jpg
the ringer11 months ago
you could also use a rounded file for shaping
Lt.Greg11 months ago
Nice - VERY professional looking results. Two comments: After having turned a few old kitchen knives into fairly neat field knives, I can tell you that it isn't as easy to get really good results, as you make it look. It takes a little practice and a lot of finesse. Also - and this is just my preference - I like serrations only on blades with which I'll be cutting a fair amount of rope. Serrations are absolutely the most useful blade type for this application, but otherwise I definitely prefer a straight blade of between 3.25 and 4.5 inches / 8.2 to 11.5 cm)
Nice work!
sschoemann Lt.Greg11 months ago
I am not the author, but would still like to thank you for stating your opinion as an opinion and not deriding the posting like others have.
neo7166511 months ago
For 99℅ of rope cutting if you try a hot knife it will make you throw your saw blade in a drawer.
only if you are cutting synthetic rope
Makedo11 months ago
I have a buck 110 that can open car bodies with ease. Also opens cans with out a problem It slices rope with out a problem.It slices with out hurting the blade and doesn't hang up on any blade nicks that have never appeared. I also have other straight bladed knives and have found a saw a better tool to use than a serrated knife. If you just want to have a knife to wow someone then go ahead and do it. I have seen many that had great artistic looks and look great on a mantel . It will give you skills in metal working. Just remember that your cutting into the temper and that weakens the blade. good job on your work looks good.
sschoemann Makedo11 months ago
no it is not cutting into the temper, the temper is actually the SOFTENING of the hardened metal to remove brittleness. Hence the name "temper". Further, stainless steel pocket knife blades are not differentially hardened, they depend on the inherent natural hardness of the steel itself and quite often have to be worked while in a heated state to make them soft enough to cut and shape.
thingy11 months ago
How about putting the serations on the spine and not on the blade? You get more length plus the blade is intact. Great instructable.
wolvmarine thingy11 months ago
Yea, most blades don't use the spine and I still haven't figured out why. Only thing that comes to mind would be that it take away from the lateral integrity of the blade since the spine tends the thickest part of the blade and bares the most lateral force.
its a folding pocket knife that would put a sharp edge in an exposed and dangerous area of the blade
spylock wolvmarine11 months ago
They do well,they tend to wear out the sheath though, I made a survival knife (straight blade) out of an unwanted saw ,and left the saw teeth on the spine.Being the blade is 8" long,its not as flimsy as I thought it would be,It worked out well.
neo7166511 months ago
Why ruin a good blade trying to turn it into a saw?
8steve88 neo7166511 months ago
I'm with neo71665 on this, if you need a serrated blade you're using the wrong tool.
Serrations have to be the same width / thickness as the thickest part of the blade above them to clear a path for the rest of the blade.
99% of serrations do not cut well, they hang up in cloth or rope, though I've had a couple of Chinese knives recently that are decent rop/paracord cutters. The Enlan EL-01AB and the Ganzo G706, some Kershaws having the "scallop" shaped serrations work as well.
Everyone to his own and all that, I have a knife that I'm trying to get rid of the serrations, this will turn it into a recurve shaped blade.
A bit different take on serrations is the Enlan Bee EL03B, it has a slight hawkbill blade with the serrations at the front of the blade. I'll try one when I get round to it, I can always give it away if it doesn't suit.
Anyway, a good instructable for those who want to convert their knives and find serrations useful.
you too are trying to equate serrations to saw teeth and the clearance to a saw's kerf. this is not how a serrated blade works, the long and short of it is that one inch of serrations is equal to 2 inches of straight blade. If you are having problems cutting with a serrated blade you are putting too much pressure on the blade while doing it, and binding the item you are cutting into the serrations rather than allowing the edges of the serrations to slice as they are meant to
serrated blades are not saws, every inch of serration equals two inches of blade surface
sctirvn68711 months ago
I have always gone for straight edged pocket knives. What is the advantage to having a serrated edge?
Serrations give the false impression a dull blade is sharp. A properly sharpened blade cuts and leaves a smooth edge. With serrations the points each grab and since the cutting "edge" is so short it rips through. 15 years of making custom knives (hobby, maybe 3 a year) its only the armchair commandos that want saws.
30 years of making them and selling them as a side business you are incorrect. each serration adds edge surface to the blade, a one inch area of serrations is equal to two inches of unserrated edge plus the serrations are not dulled as easily as they are protected by the points, and only flexible materials will reach the edges within them... serrated blades have been proven in military use, search and rescue and other critical duty use, that is far from "armchair commandos" I would highly suggest you find a hobby where you have more knowledge of so you don't go about spreading such myths, because you are absolutely wrong.
speed in cutting rope and cord, and other tough to cut materials, NOT tomatoes
criggie sctirvn68711 months ago
Cut a tomato with both sorts and see what works best *for-you*
If your serrated knife works better than your straight edge knife, you do not have the straight edged blade sharp. No serrated knife can cut a tomato as easily - and certainly not as cleanly - as a really sharp straight edged knife.

If I need to cut a small branch I get the right tool for the job, which is certainly not a knife. Of course, a truly sharp knife will go through a small branch like butter.
Serrations also give a knife for cutting surface area. Also give a ripping/sawing option on the same blade. eg small branches can be harvested quicker with a sawed edge than a straight, just one instance.
If you have to cut something tough like plastic.
ryan8816 Rambo55611 months ago
Serrations work better if they span the blade, because you need the 'sawing action' to cut something. Shorty portions of serrations like this are not as effective.
NVDevastator11 months ago
(removed by author or community request)
3366carlos11 months ago
very nice dude.
crszoom11 months ago
Cool good idea !
Mcyd_21311 months ago
I must agree, looks great for doing it yourself (and a lot better than some factory made serrations) this will help for when I start making some cheap blades.
spylock11 months ago
Looks better than the factory serrations on my Kershaw,you are a pro,I like the equipment you used as well,who is it made by?.
Mrballeng (author)  spylock11 months ago
Wow, thanks! All these tools came from Harbor Freight.
spylock Mrballeng11 months ago
Awesome,its been a while,but Im gonna check out H.F.Again top notch work..
michiganhiker11 months ago
Good job on creating the serrations on the blade. For rope, as Lt.Greg said, this is the best edge to use. I too prefer a smooth edge but this is just a great job you did. Thanks for posting.
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