Instructables
Picture of Folding Knife with Aluminium Handle
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Please remember to vote for this instructable as I put in a lot of time and effort to make this and show it to everyone. Thank you


This instructable will show you how to, from scratch, make a folding knife with cast aluminium handles. The making of this knife does not require many power tools and can be done mostly by hand. Have fun and be careful.

Display Video

http://youtu.be/nWN3pPBCulo

Step 1: Templates

I found a set of templates that were created by John Heisz. The templates are found for free on his website www.ibuildit.ca or can be found directly at this link: http://www.ibuildit.ca/other%20projects/Images/Pocket%20Knife/folder.pdf

Step 2: Cutting Out Knife

Picture of Cutting Out Knife
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The first part of this process is to find a piece of flat steel. It is better if you can use old saw blades or tool steel but for this project I simply used a piece that I found in a junk pile near my house. It is 3 millimeters thick, perfect for a knife blade. Before you cut it out, glue on the template onto the steel, and let it dry. I used a jig saw with a metal cutting blade on it but you could alternatively just use a hacksaw. I followed the lines as best I could, and after that, I used a metal file to fine-tune the edges.

Step 3: Sharpening

Picture of Sharpening
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Next, I clamped the knife in the vise and slowly used a metal file to grind the steel to a point. I could have done it faster with an angle grinder but I didn't want to risk messing up the whole blade. It is a good idea to mark the center of the steel with a marker before so that the edge of the blade is centered once it is finished. After all of the rough filing was complete, I smoothed the blade with my bench grinder. You don't want to sharpen the knife all the way just yet. Keep is dull for now.

 
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Cool :)

mperrault13 months ago
In the future, your garden hose will likely do more harm than good. Spraying water on molten metal can cause it to pop/spall and fling molten metal away as the water is boiled off. Sand is a better alternative to contain

Better yet is baking soda, also works very well when the quench oil catches fire.

laffinm (author) 3 months ago
Thank you!
dude this knife is awesome
chessman1223 months ago
Oh I'm sorry. I didn't see the rest of the pictures. I had only saw 4 pictures of the knife on one side. My app had glitched and stopped scrolling.Never mind! Oops. Very good job now that I had seen the rest of the pictures. Very good job indeed
chessman1223 months ago
Hey! Not to criticize your project in any way, but it may be beneficial to show the other side of the knife. Its just to show that you did not hide the brand name and clarify you did make it. But once again with no disrespect, I'm not criticizing or assuming you didn't make it. I was just letting you know. And good job. It looks nice
Fikjast Scott3 months ago

very well done, you covered so many aspects of making this knife. I like the casting of aluminum.

laffinm (author) 3 months ago
I was never intending the hose to be used on the molten metal, but rather if the fire were to move outside the forge and catch fire to surrounding grass. I do already know the dangers of spraying molten aluminum with water, but thanks for your concern anyways.
laffinm (author) 3 months ago
I was never intending the hose to be used on the molten metal, but rather if the fire were to move outside the forge and catch fire to surrounding grass. I do already know the dangers of spraying molten aluminum with water, but thanks for your concern anyways.
laffinm (author) 3 months ago
Wow! Thanks for the tip, I'll definitely try it.
neo716653 months ago
Coating grinding stones with automatic transmission fluid will keep them from clogging up with aluminum. It slings it all over and makes a mess so don't grind in your Sunday best at your mommas kitchen table.
Samuel kos3 months ago
Love it, I'm in the process of making a fixed blade tanto point knife right now
laffinm (author) 3 months ago
It is in the Metal contest, the Great Outdoors contest, and the Glue contest.
Survivorkidjr3 months ago
What contest is this in? I'd like to vote
adamtanner0013 months ago
nice!

Wow, gorgeous work!

laffinm (author) 3 months ago
Thanks!
Aleator7773 months ago

Gerber who? Nice metalwork!