Introduction: Folding Knife From an Old File (w/ Basic Tools)

Picture of Folding Knife From an Old File (w/ Basic Tools)

This Instructable is (not!) sponsored by all of those useless, old, rusted files that are wasting your precious pegboard space.

Why not turn them into knives?

I recently built my own Homemade Drill-Powered Knife Sharpener, so I thought I'd try making my first knife. I thought I could make it from a really old file that I've never used, because its steel is is probably hard enough to hold a good edge.

I don't have any of those fancy metal-working tools, so I tried making it with the basic tools that I have.

Let's get started!



*Pssst! Don't forget to check out more info about the giveaway in the comments!

Step 1: What You'll Need

Picture of What You'll Need

Hardware & Materials:

Folding File

Sharpening/Buffing Compound

Chemicals & Adhesives:

Water (Coolant)

Tools (+Attachments):

Wire Brush

Vise

Dremel Sanding Stone/Drum

Abrasive Dremel Cutting Wheel

Permanent Marker

Electric/Power Tools:

6-in-1 Woodworking Machine (It contains the Mini Bench-Grinder)

Drill-Powered Tool/Knife Sharpener

Dremel

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Why: I need a knife!

Recommended Safety Equipment: Earmuffs, Respirator, Safety Goggles,

Cost (for me): FREE!

Difficulty: Pretty Hard

Approximate Time: ~3 Hours

Step 2: Choose Your File

Picture of Choose Your File

Choose the file that you want to ruin! This should be an old file that you rarely use. Preferably one that is slightly wrecked.

I used a really old folding file that was made in England.

Step 3: Clean the File

Picture of Clean the File

My preferred tool for cleaning the file was a wire brush. Make sure to scrape only in the direction of the cutting lines of the file to avoid ruining the wire brush.

I made sure to add water, which would help the sawdust fall off.

Step 4: Mark and Grind the Shape of the File

Picture of Mark and Grind the Shape of the File

I started by imagining the way that I wanted the knife to look. After that, I used a permanent marker to color over the parts of metal that I wanted to remove.

I secured an abrasive cutting bit in my Dremel, and started cutting, while making sure that the steel stayed cool with water. I didn't allow it to get hotter than the Dremel itself :)

Step 5: Square Up the Grind

Picture of Square Up the Grind

I'm probably using the wrong term for this, but I used my mini bench grinder to make the grind totally perpendicular, as if the knife was never sharpened.

I tried it, and the sanding stone that was in my dremel worked well too.

Step 6: Make the Bevel

Picture of Make the Bevel

In order to make a sharp knife, you need to grind a good bevel.

I started by freehanding it with the Dremel, but later realized that it was easier to clamp it in the vise, and move the knife.

Step 7: Polish the Knife, for Making It RAZOR SHARP!

Picture of Polish the Knife, for Making It RAZOR SHARP!

I'm sorry for the awful pictures. My camera can't adjust the brightness when I try showing how shiny it is :(

I used My Homemade Drill-Powered Tool/Knife Sharpener to polish the bevel. BEAUTIFUL! If you'd more instructions on how to use and build it, please click on the orange link.

Step 8: Use It!

Picture of Use It!

Congrats! You've made your first knife!

I finally know how to ruin the balloons that ruined my motto... ;)

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DONE!

As always, thank you so much for voting!

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If you have any more ideas for future Instructables, leave them in the comment section below!

Comments

Yonatan24 (author)2016-07-28

Do you want a FREE PRO Membership?

I'm giving a FREE 3-Months PRO Membership to the first member that makes a Folding Knife from an old File!

What you have to do to be able to receive the free membership:

1. Follow me on Instructables

2. Reply to this message with pictures of the end result (And any explanations, If you want)

3. Nothing! I will PM you the free code!

Come-on, Let's make something!

spencdood (author)Yonatan242016-07-31

i made the knife, can i get free membership?

Yonatan24 (author)spencdood2016-08-01

Can you please show me pictures of YOUR knife?

spencdood (author)Yonatan242016-07-31

this is when i was buffing it

spencdood (author)Yonatan242016-07-31

it took me a long time, but it worked out

Orange robot (author)2017-06-06

And if you want it to be even sharper, you could use a knife sharpener. Nice project btw and its nice that you made it without a bunch of fancy machinery and equipment

Yonatan24 (author)Orange robot2017-06-06

Thanks... But it took so much time! :)

jtobako (author)2017-04-09

Can I find out more about how the folding works? I can't find any information on the file.

Yonatan24 (author)jtobako2017-04-11

Hmmm... Not sure how I can explain it.

There's some type of pin that allows the knife to move, kind of like these: http://www.ebay.com/itm/Key-Shaped-Stainless-Steel...

jtobako (author)Yonatan242017-04-12

Those are fixed pins, I was wondering about the sliding pin in the c shaped channel. Is it just to limit how far the file can open and close? the channel is on both sides but I don't see a hinge pin.

Yonatan24 (author)jtobako2017-04-17

That part locks it in place, so it doesn't open up accidentally, and so it stays locked once I open it.

The locking mechanism that's in my Victorinox pocket knife is way better then this.

spencdood (author)2016-07-31

i in fact have made this awseome knife

About This Instructable

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Bio: 15 year old, sick with a deadly disease called DIY-itis!
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